SERVICE - Beautiful Vintage European Pedal Mopeds · SERVICE MANUAL Thh Service Ha.nua1 bas been specially prepued tor the use ot our C,ady S•rvielf19 Agent.. tn SC*t a.r.._, lt

,..,

SERVICE MANUAL

Thh Service Ha.nua1 bas been specially prepued tor the use ot our C,ady

S•rvielf19 Agent.. tn SC*t a.r.._, lt. .. y

appe•r that ve have been ~oo explicit but we have taketl into account t.hat

there may be many consumer g ~ho wiah to have such a oanual. The technique• tecoanended in t:his manual are t.hoau

which we employ and teach in tr41n1n9 CO\II'Itl.

* NOTE• To t.be consuaer end the ettvlclna dtdtr

It ls expTessly underatood that under tbe ter.s of tbe Cady Warr1nty, eny d.._&• e,Juaed to any p•r~ or pn:u or the Cady

motor or machine by ute or tooh other ... t l

than SPECIAL TOOlS II H•tld ln thh

SERV!C£ MJJIUAJ. wt\1 not lbo covered by t:he Warranty

* W'het:e •n ope-radon 11 detcdbed •• "Left Hanel Side" or ·~tgbt Hand Side" thlt la deter.ined •• vben the rlder h se1t~ on the ••chine ln the norul pnner.

USEFl'L H't'rRJC CO~'VEBSIO!iS

1 -(ro1Utmetre) ... . 0394" (Inch) 1 IMPERIAL CALLeN • 4,546 Hu.t

t ""' ( cen Hme tre} = .394" (Inch) 1 u.s . C.UUJI/ • 3. 713 lttru 2.!54 em ( .. } . 1.00010 (lnch) 1 IMPERIAL GAUOH • 160 n.oz.l .

1 U.S . GALLON • 128 n . oaa.

I

I

Basle Tool Requitement

&el t B&lt - reptaot~nt

Btl t - tension &reak~n

&rake - &dj ue:tment.

Brake cables

Botto• bracket

Clutch - Removal Clutch - Servicing Clutch - Refi t.tins ConYct Br eak.ets CyHnde·r held - re'l!IOVIl

Cylinder hud - refitting Cylinder - removal

cylinder - reficttns Cyltndet/Pli~On Hatching

Cerbon

Ch•tns - Care and ·Repbeement

Chat ns - ad jus tmen t

Chain tenatoner Cranks - crank pins Cotter ptna Chainwheel

25 25

PACE

3

7

8

8

12 29 30 49

9 10 10 12 15 20 15 20 19 18 21

-26 -26 23 23 24

'::)..~ .:r0€"t> \ ow.vt SERVICE MANUAL

Cables ... bnk.e

C1bles - thTottle

Cables - choke Ca bhs - deco.mpr~ssor

Cbokt - cable Carburettor - servic~

Conv•rtor crantt a.xle

Drive belt

Drive belt - repl1cement nrive belt - t .enston Double clutch - removal Double clutch - atrvicins

Double clutch - reflttin6

oeearboniztns Drive selector

Drum brak.ea Decompn:•sor Oeeomprt,.O't C-1 bl e

E·nglne - nmoval

Enstne - reflttlns

Enaln• - t1eina Enst.ne - aprocltet Engine - nUIIIiber

INDEX

PAGE

30 32- 3S

33 34 33

37 -38- 39 22- 23

49

1

8

8

9

10 10 18 23 30 34 34

6 6

13 24 S1

Exhaust. ptpe

F'ore~ord

Flyvhe6l - rt~oval

Flywheel - refitting Fr<mt \lhe e l s fronc bt'akes Forks - re#r Forks - front

Forks - servtcing Fork lock frae.wheel Float

Fault findtng Frame n\J!Ziber

Cas c able - adjustment. Cas cabl~ • replacement

Hubs - servicing Handt•bats - adjustment

Ignition - timing lgnttton - checking

L.ockt

Lubtica tton

t'age 2A

54-

~

18

1

11 13 27

29

41 4.3- 44-45

46 47

50

3~

55- 56-57 51

32

35-36

32 48

l3

14

to?

52

SERVICE MANUAL Im&x

!ill Motor - re111oval 6 Motor - refitting 6 Magneto - remova 1 n Magneto - refit.tl.ng 12 Magnttto - cam l1 Magn~to plate - removal n ~agr.eto plate - refttting 12 Motor - t iming 13 Mixture - fuel 56 Muffler 18

Obsolete engines 5

Points - setting - gap 12 Piston - removal 16 Pis ton - refitting 17 Piston rtngs - f1 t<lng 19 Piston/Cylinder ~tcblna 19 Pulley - remove! 22 Pulley - servicing 22 Pulley - refitting 23 Pe<la l s 40 ·p1uss 53 Pedal axlf! 47

Rtnss - pis ton Rear wheels Rear forks

SpecLil tools Stator pl1te removal Stator plate - refitting Shock absorbers Se1:hl numbtt:l

Tools - bade

toot. - spechl Tlllling Throttle cable adjustment Throttl• cable replacement Technical data

Tank capacity Telescopic fork~ T'roublt thoottns

Use of special ~ola

~'V" Belt

lrlb4el• - front Wheels - r ear

PACE

19 28 • 28A

41

4

11 12

42

51

3 4

tl-14 32

35-36 53

53

44-45 .. 6

54-55·56·57

1

7-8

27 28

SERVICE MANUAL

Pflge 2B

I

&ASIC tOOl. R£QUlREl!E~"TS

DESCRIPTION

GREASE GUN (WITII MINJA'TlJRE NOZZLE)

PWC ~'RENal 14 ..,

!0" SCR£W!lR!VtR, FLAT BLADE

-z PI!ILLIPS SCREII'lRIVER

OPEN/BOX WRESCIIFS 611111 nrROUCH l4• tn1 1~

HRTRIC NUT DRIVERS Sme 111ROUCII 9mm

BATTERY 7ERMINAI ~RUSII

7" PLl£RS

LOSG •OS£0 PLIFRS

12" ADJCSTAILE VME~H

DESCRIPTION

FEELER CAUC£5

CIRCLIP PLIERS (I~<)

CIRCLIP PLIERS (EXT)

11.011 TORCH

•- IIEX KEY (LOSC TYPE &EST>

5cm IIEX KEY (LO~C TYPE lEST)

METRIC WRENCIIFS AND OR SOCKETS 6""" - a- 10- 11 - 12 13- 11- 19m,

HULTI LOCK PLIERS

001/BLE E~l>ED !'[,OAT. WRFSCll

HAH!!ER - RALL P£1' TYPI

1191

FLY1111EEL VISE

15141

CLUTCH PULLER

98952 PEDAL WRENCH

TIMING CAUCE

SPECIAL TOOLS

1390

MAGNETO CAM PlJLL£Il

1434 PISTON PI N TOOL

G 4 5 1486 CAM FIXING TOOL

t7650

~SERVICE MANUAL

O&SOLET£ E'CI'ES

A WORn OF WARNll'C

MR. DEALER ................................................ ..

OVER TRE PAST P~' YEARS A CeRT~lN NUMBER OP MOfEDS (AU1UCYCL£Sl UIWE ENTER£D CANADA U$1tl('; ll11.81CALLY THE SAME ENGiNE AS IS

PRESSNTLY USED ON THE CADY MOPEDS.

IT IS CONCEIVABLE "f'tU\T YOU WILL ROCFlVl SOME ENQUllUES

roR PARTS FOR "MIESE FORBRUNS£RS AND WHEREAS Q011'E A P'£'W

CADY PAR'l"S WD..L BE lNTERC'HA~CEA81.E TlttRt. WILl. BB OTHERS ':'HAT

ARE NOT •

VARIOUS MOOl.PICATtONS ldi'D IHP~ HAVE BEES K~.D£ OY!:P THE

PAST PEW YEARS W.ICti HAVE' PUT CtPTAIN PARTS Or 'fti'ESE 0!.0-ER

MACH!NES Th'TO THE CATT..OORY or "O&SOL.l"TE". A'I' 'Th*E S.~ TIM£

1i-1ULS't' YOO MAY NO'l' IE ABLE TO R.!Pt.AC£ AN EARLIER PART IT MAY

Bt POSSIBLE TO REPLAC£ 'MiA 'I' PART WHEN tNCLUOEO IN A SUB ASSEM8LY.

WliF.REVOR SUCH lllST~CE$ ARISF. PLEAS£ CHECK OOT TK£ PAR't THOROIJ<:IILY

AUD WHEN IN OOUB1' PASS YOUR I~QUlRY THROUGH HOME OF'F'ICE WHERE

EVERY A'l'TBN"l'ION WU.L f!E. r.IvtN TO PROCUkE TllE NeCESSARY P1\RTS.

SERVICE MANUAL MOTOR REMOVAL & REFITTING

NO SPP.CIAI. TOOLS 1\EQUIR£0

NOT£a for e.ny ttrvlet optratlont 1t lt not necessary to remove ~h~ eo.plete •otor.

~uch optrttlont 11 Minor decarbontzins - Cheektns tbe timing -Clutch removtl - I,nltlon checklns etc. , caa bt earried ou~ vlth the ensint in pltct. (l! the wachln4 1• elevated to bench level by Whlttvtt .. 1n1 rut~• you bes~, mos t servicing and repair job• can be carried ou~ efficiently and JUCCIII(Ull.y.)

RDfOVAL

l) ~e.ove both chtln eov.ra UY & lU aide• 2) Looee n upper •nslnt ~vntln& bolt ("A" Ftc. 6-1) but

do not re.ove. l) Looeen tnd "reeovt lover enalnt ~untlns bolt

("I" n 8• 6-t> 4) Sllp dtlvo bolt orr lot80 pulleT S) R•l•••• dtcoepreetor ctblt by acrevtna tn c t ble

adjutttr on R.H. lever . Nov prttt down on decoep~ssor ('"C" Fla. 6-1) retea .. outer culna !rca top of dtcOIIptet tor t nd l.nntr vl.re nl.pple fl'a bucket. •t belt of deco•pr•••or .

4i) Remove Hshtlnl vt.u !roa~ easneto t t a tor pt.1te ( "'D .. Fis, . P•se 12) tnd aperk plus cep fro• ap•rk plus.

7) Remove c• rbunttor by ehckentn& tc"t'eV {""D .. Fig. 6·1) &ently rotatt cerbunttor ltft 1nd dfjht to remove front tntlkt ptpe. Th• carburettor can now b•ng freely.

8) Th4 motor ctn now be removed by holdins lt ftt'mly while removlns t he uppet' enslne bo\t "A" Fla. 6-t)

R&FITTII!£

9) Reverae the oper1tlon when retlttlns t~ motor maklna ture the cetburettor tt pushed a~l the way onto the i.nttke pipe.

10) Retdjuat the decomprttt or ctble allowin$ a little alack in the cable. See Pitt 34 OeeomPTeJtor Adjustment.

o -

Flg, 6-t

A

SERVICE MANUAL DRIVE 'ELT

1(0 SPECIAL TOOLS REQL'rRED

the correct tenalonlns of the drlve belt il \•porunt to tbe pe-r!on.nc• o! the .otor. A "tigbt" belt vill cut down performance al allo vlll a ''tlack" bltlt and botb c:ondl tion& contrib\lte to belt wu·.

Any excets tention f~om 1 tl&ht bel t will •l•o adn to the wea~ of the ~renksheft be1rinss.

Host t'ailures t.n bttlta can be <:ontdbuted to .. l) Using a non orl~1nat drl vt belt (t.h\~ \1 the aost common). 2) Too much or too ll~tle tension . l) A verped pulley (diiNI&td) .

6 ·' deformed or d .. nt*CI pulley groove .

S) lettroper 1Hpeent o( the belt due to a tv\ated frame or motor , or ~nt pedal cran~ tha!c.

The tension on the ddve belt should be tet •• ducrlbed on page 8 to allow for • deflection of the belt or approx. 1/4" to 3/8" ••• Fls . 7-1 . You misht -run lnto I litVHlon where the ens1ne " pu lsates" whtrl belna drive and thb h very ofun e condition ~IUitd b)' the belt lll!int Vor:n narrow in on• area due to excessi ve revvinA of t:be. motor vith the ma~hin• st.atlonery. A good example it revvlnk the ~otor for ~ quick sec-•~•7 at etop lights . Alv1ys check thtt tbt belt does no~ have any narrov (wotn) tretl tnd \1 not showin& 118"1 of crack1nA and eeperatlon. Properly cared for the drlv• belt w11l be the least of your ptobtems .

Whf!n ln doubt alve)'l roplaco the belt v l th en original equipnent bf>Lt . Thh hfS been tpecifictlly developed for C4dY mopeds for long 1i fe .

Fla. 1-1

Ca-cf..rl SERVICE MANUAL DRIV£ •ELT REPLACEMENT & TENSION

l) ~eeow L.fl. Chdn Cove-c

2) Loosen upper •otor eountins bot;. "/l"' Fl&• 8•1 3) Loosen tower a.otor mounting bole "8'" Fts. 8 ... 1,

on some .. chtne• too1tn tll~ the belt adj~stera. "E" Ftg . 8-3 . The motor ~an now be ptvotttd to the reat on the upper mounting bolt sl•ck~n1n& the drt ve be 1t..

4) SUp r.he ddve btlt off from t.he bottom of the large pulley ., •• Fts. 8-2 1nd rotate tht pulley anr.1-clockv1,. vntU the belt l.s frte of the pulley. You can nov force Lhe belt froa und.,r the plae~lc cover and off the cluteh without ~-aovt.na che plut1c cover '"C"' flg. 8-2.

flg . S-2 Pig . 8·3

NO SPECIAL TOOLS REQUIRED

B

na. s-1 S) to replace the dr1vt belt, reverse the above

proceedurt end ten•t.on the belt correctly as fo llowa .

6) On aacblnee wi thout belt tensi oning •djulterl , plvo~t the ~Dtor to the front Ul'l~il eny be\ t e1ack ts t aKen up and then tighten the lover 100tor ll()Untins bo1 t first • nd then the upper motor eount1na bolt.

7} Oo a achlnu w1 th belt tension ins 1<1 jut ten .Sjust. both equally. See ••£" rtg. 8•3 !or locatlon.

8) M.ake aure you cen dept'e&a t.he drt ve belt t/4" to 3/8" before loeJrl.os the adjutten •nd t1ghtent.na the enstne mounting boltl . see fts. 7-1, ~~· 7 !or chtckint belt tension .

SERVICE MANUAL CLUTCH REMOVAL

!2!!.• tbh operation can b. perforMd vl th tbl ~tor on the ••chlnt Ot' on the tletlCb 1c a viae.

[( chaped ln a Ylse do not onrtlshten end .,Itt aurt tbe lower ItO tor IIOU'!'ltlna bracket 11 at d sht •nste• to the vhe J•vt. Fibre pad a should be u.td 1n the viae j1va.

1) lflemovt plastic cover "A" Fla. 9-2 uat.ns thln bl~ed screwdriver between edge of atator plate end phlt.ie cover "8 .. F'is. 9-2 it 11 a snap-on Ut end fdll anap by sently pryt.ns a t 3 or 4 pointe •round the ~se.

2) nshten universal vhttl vice tt\291, "C", Fls . 9-1 on flrwheel ' 'D" Flg. 9-1.

3) Remove clutch drum nut "E" Ft.s . 9-2 (R.n . t hte1d}

4) Screw clutch pulleT #1S141 into hub of dr\m ate ••r" F\s . 9-1 (keepln& • flrm sr\p on tool 1291) and progruttvely t:1gbten centu acnw "'C" rt.a~ 9-1 (R.H. thread) . The clutch drue .'tf .. Hs. 9-2, vhlch la spllned to the crank ah.tft vtll nov pull off easily.

c

SPECIAL TOOLS REQUIRED Order of ut e l Flrwhtol holder 11291 1 Clutch Puller 11S141

5) The clutch bub ••ae•bly "J .. Ft&• 9-1 can now bt pulled off the abaft . It aay bt neeesaar1 to cum the clutch hub a little left or rlght to line up the g-roovea tn the clutch hub wi th the &roove a on tbe crankshaft befOTt lt vtll pull off eaaUy.

Fig. 9-2

6) Never force the clutch dtt.DI off vith levtrs . The clutch ts a tvo piece un1t and unltaa nverely damesed it will be ta a11y ~•moved vlthout force.

7) It severely damaged t.ntptct th cranktha ft and ensure 1t ia not bent.

8) To refit the clutcbtl rtvttte the above prooeedure making SUTe to llne up the epllntd wteher - no force needed.

SERVICE MANUAL CUJTCH SERVICING AND REFITT{NC

NO SPECIAL TOOLS RE911IRED Witb the doubl~~t clutch reeoved proceed as followa -

The SECONDARY clutch Fig. t0-1 This la a very simple at'e damage to the drum and ... -ear on the t:luccb U.nina,a. but aenerally it it best to replace tbe co•ptete d~um. the rivet heedo 1na1de the drum after r1vett1ng.

mechanism tnd the thln&s to check to~ The clutch linioga can bt replaced

If repl•cin& the linin&• smooth off

The PR~Y clutch Fis. 10-2 incorporates a needle bea~lng and thla r tqulres lnapectlon from d. me to tlmt . The clutch dt'Ufl) should be checked for damage and the clutch llnt.na• fM wur. to rentove the needle be•rt.ns. L) Remove the circlip "E" (internal cL1:c11p pliers) 2} The flat washu ' 'D" (larger than "B .. )

3) The ep11ned washer "C" 4) The flat washer 108" (sma11et t hao ''!}"}

S) The neecfle bear in& "A"

6) Inspect the inner bearing surface of the clutch drum for w.ar and or corrosion pit ear~• · ria.l0-2

7) To reaneTOble reverse the proceedU'te above TOtklng eut'e t.be betr1.ns au-rfacee and the beadng are absolutely clean and t.hen greued v1.th a gt!ntral. purpose greue.

To rem.ove t.be clu tch shoes -1 ) F1..1e off the avaged end of the pivot p1nl "J" Fig. 10-2 and remove the plain washer ••K"

and vavt vath•r t•L" and then the clutch •hoe• with linin& 1pd unhook the tprings . 2) Reverte tbe proceedure toreflt the elu~h ahoet. Lubricate the pivot pins first vith·

a •~ear of seneral purpose grease . Swage the ends of the pivot pine ~o aecurely hold tbe clutch ahoea in place .

H&.10-l

lbe double clutch ceo be adjulted to allo~ for by hooklns the springs in the holee nearest to

s&artlng a t each other.

a lover spe•d. Tbh see "If" Fls . 10-2

is achieved

To in1e.ll the Double euto•atlc clutch~ 1) Push lllell'lbled clutch drum "F" Fig .. 10-2 on the cunkahaft aligning spliced 11a1btr "C" with

enn1tth1ft 1pl1nea allollin& tbt clutch to .tUde all the vay on.

2) Place clutch dtum "'C" ne: . 10-1 on spUnes on the abaft, push on aa far as possible and finally lnnall clutch nut and tigb~en . Hold the flywheel vlth tool 1291 txt securely t ighten t .he clutch nut. See Fts . 9-1, pase 9.

""" 10

SERVICE

,.,.II

MANUAL MAG'ETO• n.\'1/!iF.F.L ·~ STATOR PLAT[ Rf'!<OVAl.

SPECIAL TOOLS REQUIR£1'1

flywheel Holdor ,1291 H~gnt~o Cam Pullet 11390

After t~~ovins thu clutch {see paee 9) proc.ed as followaa• 1) Oisconnect the isnition wire <••etl vir~ vith tpade termtn~l)

from the coil under rhe funl tank and tht li&htinp utrt Jt stator plate (alto sp.a4e c.erain•l) "K'' and "'L" H~. 1l·2.

2) Tigh~n univtra•l vbeel vice #1291 onto flyv~l •~• ''A .. Fi~ .. H-1 •nd r4!'1110Vt flywheel nut and v .uher ''C" F'l6 · 11-3 (.P.H. tbt•Ml) usln~ \on" 24-m. vrenc1'1 "'8'' fl«-11-1 The flywh-tt'll h nov fre@ to bf. rHIOved. The "Ntntu vt ll cause s~ rttl•tane-.

3) Using eap,nt>ro cam puller Ul l% "C" f'ls . 11 -11 removt c11m "'tt" fi~ .. 11 .. 3 fcc. shaft by scnvln8 puller "C" on Clll "W'• hold th'!: puller vtth a vrench •nd screv in centre bolt •-n•• fi&o ll-4,

4 ) To reaove ltttor pbte -&:'' Fts, . 11·1 •t.aply re.ove tht tht1"e Allen ty.,.. terevs using~ • h~x key, see "f" fis. 11-2.

~H I .I;-\ ~· ~, ! /.-~ ---D

I ' '

Fla. 11-3

Co.d"'l SERVICE

• • • • • • • • •

• •

• • • • • • • • •

.:fjc :... ' ••

8

E

MANUAL MACNllTO• STATOR PLAT! ASSEifliLY -CONTACT IUAI<U SETTIMC

NO SPECIAL TOOLS UQUIRED

STATUII PLATE

1) llephee the Stator plate by renra1ns proceedure 4, on P•&• U m.akins sure R.T. vlre .,., ltghttns tennlna\ lt't t.n 1 o'clock polltion "D" fls,. 12 ... 1, Jnd Untns up the 3 hole• fot the Alten type serevt. Stt location "E" f'i@:• U-1. USe Locktl.tt lnue Locking Cement on tht •ounting aereva.

CONTACT BREAKER SETTING

2) Pltet au;neto e •• ''C"' Fla. 12-2 a•ntly onto shift snc1 route to obtain uxt.au. bruker &•P· At thh point adjuat tbe polnt gap to 3/10 .. (.012"} al follova •

3) Looatn concact breaker ateUTtna •nd turn concentric c .. "8"' Fla. .012" uling • ftel«r s•u&•·

acrev ''A" ns. 12-1 12·1 to set polntl to

NotA 1 Tuming the e•• "&" tnt1-c10<1kwlle open• ttwl sap 1nd elockwite clo••• tht &•P•

A) Ttshten locking screw "A" ltcunly and double check polntl &•P h still .012 .. •Ad has not ch1nged •

Fln1l f1ttlns of flywheel 1nd ••sneto c•• l• de1c:d.bed on P•&e 13.

Cc:J..d..«f SERVICE MANUAL MAC!IEto FLY11HEEL REFITTING Am TitliNG THE IGNITioN

1) Havins set the contact breake1:s, 'J)3ge 12, proceed as follows

SPECIAL TOOLS REQUIRED TIMING GAUGE # 1470 FLYWHEEL YISE #1291

2) Remove the spuk plug and screw in the timing gauge ~1(170 finger t ight . Flg. 13-1.

3) ~otate tbo motor clockvlso until pls tom Is ot T.D.C. (Tbo atom of timing gauge fully •xt•nd•d). 4) Una crew the t11Di.ng gauge slowly und t the shoulder

of the tool reaches the bottom of the YELLOW ~•~k on the. s tem . See "6•• Fi&• 13-1.

5) Turn the moto~ clockwise until the yelLow mark dtaeppeara about 1/4" below the shoulder of the g.auge and then rotate the motor very slowly and--clockwise until the YELLOW eat'k just becomes vlalble -DO NOT rotate ~e motor again until you do the timln& check, s ee page 14.

6) Place the magneto cam over the crankshaft onto tbe tapered tection, 'COtite the eta anti-clocltw1.te and Jtop as a.oon u a resistance. is f•tt. (This h wben the high point of the c1m comes \n contact vith the plastic pad on the moving breaker arm)

7) Uslng a a<eel tube 23/32 l.d. x 7/8 .. o . d. x 6 .. tighten the cam onto the crankshaft by lightly tapping wl:tb a hamme'C (Final ti&htening v111 be made when the !lywbeel ta installed. See Fig. U-2.

8) Before you refit tbe flywheel, double ~heck the ti~ln& in case the cam slipped when being tapped into ~osition.

9) Place tbe flywheel ove-r the eranksbaf't and onto the caa 111klne $Ut'e the two studs (inside the flyvheel) are lined up and engage in the cor'Ceapondin$ holes in the cam. The flywheel can be rotattd in eith_er direction to ltne up the studs v1. th the holes. Hold the flYWheel in pllce, plece th• veshe'C ov•r the cam shoulder and screw the flywheel nut on fin$er tight. (f\tt tl4e out)

10) Hold the flyvbeel v1tb tool 1291 and t.ighten the flywheel nut. see F18• ll-1 Pfgt 11.

NotE: See Page 14 for timing. ebeek.

--1470

Fig . 13•1

Fill• 13-2

SERVICE MANUAL ICNITIOS TIHINC OIECK- EXI'EB!IAL' (1<\UNAL

SPECIAL TOOL REQUIRRD

Ti•t~, a•uae I 1470 Fl:rvbool vho I 1291

lltvln& COIDpltte the optratlons on pt&e 13, proceed •• follo'lia TKTE!NAL W1 tb tlming aeuse instilled, flywheel re•oved. 1) ROtltO tbt IOtur clockvtso till the 5hlft Of the tlalo& SfU&O oOlf protrudos opprax. 1/2"" 2) Open the contact bTt1ker pointe and pltce • thin lt1f of ptper becween the eonttct be1ds

(cte•r:etto paper h lde1l) or • feeler s•u8• o£ not mote then .002" . l) ~otate tht •otor •lowly anti-cloekwiae &ently pullin& on the paper until lt pulls out

froe ber:wtn the con teet bude 1nd at.op c.be rout ton tbtre. 4) At th1e moaent the breaker polnta start to open •nd thta it tht exact point of tcnltlon

end the top of the yellow matk on the stem of the tlmin& 81Utt ebould jult be vhible and in line wit~ tht ahoulder o( the tl•lns gaust.

S) R.ephce the n yvbeel at deactlbtod ln t-ctloo, g..10 paqe ll.

EXTERNAL Wlth motor o~ ~ncb or on ~chine, fully alttmbled . \} Remove apark plug ard screv in the timlne e•use #1470 fln8tt tlght.

2) &o~u the aotot" until the tte.a of tl•lnA &•us• h fully extended, unaerev the tlalos &•use eo the bott• of tbe Y£LLOI atnk lt level vtth the thouldtr of tla1ns saurs• <••• rls· t•-<>·

l) With a tlmple lo~ voltag~ (1 . SV to 3V) continuity tester, lttach one lead t.o tho HIGH TESS!OS fEED vlrt (Crty virt at bot to. of H.T. Co\.1) and the other to the cylinder ftna. see Fla. 14- l.

4) Rotete the motor clockwise till the YELLOW .ar• dttappears and then slovly rotate the •otor antt -clock"lse.

S) While rotttlna antl~c:lockwitt obterve t~t light bulb and you vtll notlct • €1lcktr ln the llsbt. Thll OCCUTI It the .amen~ Fl&ol~-1 the contact breaker• open and the top of tbe YELLOW .. u. thould just b4t vb\.bh •t the aboulder of tlm\ns sau&•·

6) t! the ntc:ker ln the light tnd the YELLOW matk do not coi.nolde aa duort.bed i.t v\ 11 be nectuny to re-ttM tbt lanttlon, see pase 13.

SOT£r Tbr!' d•lnc of the- lanl.tlon h 1.1- amc vhleb la tqulvtl4Dt to ~/4"' of rotation oa the - outalde dlallltter of e-n. tlyvheel. l':ttg. If

,. .. 15

SERVICE MANUAL CYLINDER HEAD AND CYLINDER REMOVAL

NO'l'B: This can bo done with motor in frame but can be better ac<:ornpUshed it l'tiQt..or is removed. see page 6.

1) Ftemov~ motor from frame and remove exha.uet usembly 1.1- 4te.;rU>ed on paqe·t 6 & 18.

2) Clamp motor in bench visa using the lower fi'IOtor moun~:inq bracket. see il.lustration bolow.

J) Cyl1nd•t' h•ad can be removed by unscrewinc;r the fo\a' cylinder h•ad bOlts using a Smm hex ALLEN ~ype key.

4) To r~ve the cylinder use a 5 mm Hex Allen type key and unscrew the four cylinder bolts {sunk into lower part ot coolin~ fins) be careful not eo lose copper washers used on cylinder bOlts A$ they may be left behind when you remove bolts. The cylind.o..t can now be pulled up and off Uie piston quite easily.

5) There Will be a metal1Zed head 9&Ske~ anQ A paper cylind•r base 9a$ket exposed during chis operation. These should be disc:llrde<l and ~aplaced with new ones.

NO SPECIAL TOOLS lt£QUIRED,

fig, 15-l

~SERVICE MANUAL PISTON REMOVAL

REMOVAL Havins r .. oved tbt eyellnde-r head and cyllndtt p-roceed •• follova

1) Cl1mp tl'lt cunkcut tn the vtoe. 2) Rtaove p1tton pin clips, (use needle noae plie-rs) and platon rtna•·

SPECIAL TOOLS J.EQUUED

Ploton Pin Tool 114)6 vltb du..y pllcon pln.

3) Hut pilton vith blowtorch directed onto top of phton to ebout 212°F (100°C) Itt Fia . 16- 1 and vi th the cSumay ph ton pin placed 0\'l't t..he pht.on pln tool #1436 tnnrt the end of the tool l.nto the pll ton p·ln and tpply • pnttr preuun - 11 the cornet beet h ruched the eppUed p-retaure vUl P"lh tbo pill out. s .. Fla. 16-1.

4) Pbce thl phtoo on tbe beoneh end plece the cytlndtt over the piston. At (1rat tbe crUMec vUl not. drop over the phton but u the piston cools doWTI the eyllnder 'IIi 11 stovl.y sllde dovn OVIT tht pilton. Thb doel U fO tblngl 1. It tllovt the piston to cool evenly and 2. Illim1ntttl any dtatortton.

Pin

SERVICE

REFITTING

With Ct1nkc1se held \n the viae

MANUAL PISTON REFITnNG

SPEClAL TOOLS REQUIRED

Piston Pin Tool 11434 with dummy piston ptn

1 ) Make su1;e the pi ston i.s being tbe cor1:ect way. The small bole "A .. Fig . 17-1 hcu to t he ru r of tho motor.

2) Insert the small e~X3 ntedlt bearing into t.ht conntcdns rod_, position the piaton over tbe connecting rod and insert the dummy piston pin into the needle bearing to secute cne piston in ita correct pl l ct .

3) Have t he tool 1434 ready with the piston pin placed over the piston pin tool rlght up to the shoulder ••e" Fis . 17-1 . If possible keep tbe piston pin cbtlled for easier replacement .

4 ) Meat the: pis ton as directed, on page 16 and vhen heated sufficiently pl•c• the eX))Qsed end of the piston pin tool into the dummy pin end push the piston pin tool wi th the pis ton pin into t.be pis ton in one • ovement as far as the shoulder "C" f ig. 17-1 wt.ll ellov.

5) Th.e duaoy pin 1a pushed out and the ph ton pin is nov ptoperly cenu;ed.

6) With tbe piston rotated to the T. D.C. position, place tbe cylinder over the pis ton a nd allow it co cool , in the s1me manner as descri bed on p1ge 16.

7) Remove the cylinder 1nd replace the piston pin clips 1nd piston rings. See page 19 for correct positioning of piston rtngs.

8) Lightly lubricate the piston pin needle bearing witb SAE 30 oil or a soOd grade ·~o Stroke" oU .t~nd •ake $ute the pbt:on moves l1~enlly 1md freely on the piston pin.

Piaton P1n

Fts. 11-1

P~ge 17

Cc:v-1 ... , SERVICE MANUAL DtcARIIQf!ZfNC

NO SPECIAL TOOLS JEQUI&ID

NOTEr Carbon but ld·up ts cownon to moat tvo cycl e enginu tnd h the ~ott U kely c•u• • of poor pedon•ne-e. The rflllo\111 of on bon fro. the C~y enst.ne lc • 1i11ple opend on "~ should be perfonled reauhrly .

Kl~OR DECAA~lZtNC • ~tor in tM fr ... 1) Remove tbe 2 txhauct flln,• nuu and vuhu·a ''A' ' Fi&~ 18-1

2) Rtftlove the autfler c hmp bolt tnd nu t 11»" Ftg. l8-t 3) The .uffler 11 now free to work on , on the bench. 4) ruH tht exhauat pipe out of the 1111.1ffler an<l

tt~ any c•rbon and clean thorousblJ. Olacatd th• two saaketa one each aldt of the exhauat plpe flange •nd replace with nev ones when t'4•1Uelllbllnt~,.

S) ll~move tb-e bolt "E" Fig. 18·1 •t end of n~U!f'ler and then re.oV'f" the end cap ''F" rts. 1"-1 end etten out the te\1 ploe~

6) At'aove the blfflt phte "r." Fl~.18•1 and c\un out the hotel in it.

7) CJun the hoh '11" Fig. \8-l in the inner fhed turflt phte.

8) Jntpect the exhaust port ln tbt eyllndtr end cl•an thOtoutbly. t t .. , be necenny to scrape the c:artlon out (bt careful not to d•••&• the piston). A final c\unin& can be done vtth a battery ter~tlnal wh:t bru.sh.

9) R•vtrse the proc .. dure ~o re-lllemblt. MAJOR DECARBOtUZINC - Hotor ln benc:b vise Carry out the ••me proceeduTe for e HJNOk DECA~IO~lll~C end •l•o

na. 1s-1

\0) Rtmove the cyltnder bead and cyllnder. Itt Pt&e 1S and rn~ove the carbon fr·om t.he cy\lndtr hrtad. 11) 8tfort eleantna the piston heed and piston rins sroovt• rotate the eotot so the pltton is at T.o.c.

and protect th4 cran~cal~ by vrapptns a cltan cloth around t~ connecttn& ~ to ltop any carbon faltin8 into the cr•nkcase.

12) R•-ove tbe piston rings and ecrepe out any carbon in the piston rlna arooves ( a broken pltton rln!J 4111tr:a • "00(1 tcraper) and clean the pilton head.

13) Rtverl~ the PTOCtedure to ttlleeeble usln& new saakete vhere nece1s1ry •nd nev pilton rings \f required. See Pt&~ 19 for Pitton Rins rttting and P•&~ 20 ror Cyllndtr and Cyllndtr Head rtftttlns.

,.... 18

SERVICE MANUAL PISTON RING fiTTING -PISTON TO CYL!NilEl\ HATCHING

NO SPECTAI. TOOlS REQUIRED

TM Httina of piston rtn&s ia very el•plt - )uat folla- tbe notes belov

FiJI. 19-2

NOTE "A"' Tbere are pbtoo rlaa ant1 wmln, uopt 1n ~::t-• pt.uon rlft& croo••• of the piston - ad::e aurt the rtnat an tbe rl.&ht vay to catch tbt stops ln ehe phton. Ste fl&· 19-1.

Natt "&" AIUliN&h then an p11~n• ,..nu(fctund to .. tch up v\tb apeclflc cyllndeTs the rinsa art all ont tl1t end flt all ph tons. NO "GAPPING"" IS BEQUTRED.

NOT'£ "C" When repbelfls piston ttnss on • uttd phton 101ke sure the pltton rina grooves are fret of c1rbon. A t1mplt eethod of cleenlna the grooves is to sn1p tn old pttton Tina, •nd witb I piece tbout 1" long and aquattd Of( It tht tnd On a gr1nd-ltOOt, carefully scrape the carbon from tht grooves betna careful not to remove any metal.

PJT11NC To reft t tbt rlns,s stmply spre1d ••ch t'\ns apnt just enough to pt&a over the piston, lt lt belt whtn servlclns 1 ~otor to al'fiYI fit new piston rings.

Platon to Cylloder Matcbtng See Ftg. 19-2 SOTE "'D" Cylinders ar• alvaya tUJ)l)lted with aatchln5 pt.aton.a.

SOT£ •"R" It 1f h neeetsary to rephce a piaton or.ly, first identify ttw cyUnder by th• let.ter tt..•d on the top face of r.be c:y11ndtr and ord.tr the pt'Ct nu.~r ICC'Ordln& to the chart btlcnt.

EXA.."'fPU: t- If cylinder 1s aarll;ed •f • or ·~·· ute cylinder pan nmbtr 19187.

~ ijse BC .. DE " FG ..

PISTON CHART

Part 19199 •• 1918~

" , 9186 " 19187

H J Uu K L " M tf " 0 p ..

put 19188 •• 19189 .. 19190 .. 19103

SERVICE MANUAL CYLINDER AND CYLINDER HEAD REFITTING

NO SPECIAL TOOLS REQUiltED

Crankcase held in vise NOTEt Use nev gaskets vhen car~ytng out th1a operttion. 1) Make sure tbe cylinder and cylinder bead are perfectly clean especially the contact

aret between the ~rankcase and cylinder and eyllndtr top and he,~t }'(f-ke sv;e the two halves of the crankcat .. are lined ~p and fo~ flat eurftce 10 1 propt~ joint can be mtde with the cylinder.

2) Lightly coat both aides of cylinder base gtsket with &tneral purpoae grease and place it on the crank cue - maktns eure 1~ ie correct wy •round.

3) With piston assembled lightly lubricate the pitton ana pilton rings ~lth SAE 30 oil or aood srade ''Two Stroke•• oll .

NOTEt Tbe cylinder bore is chamfeTed It the base to allow eaay entry of the piston rings when comprt'ued with the fingers . Each piston dng being coepr.11ec1 on~ at a time as the cyltndeT l$ tnttalltd. A slight Totation of the cylinder both left and Ti&ht will b~Up .

4) Rotate crankshaft ao piston 1a at t.o.c. petition, compress the piston rings witb your fingers (make ~ure they are lined ~P properly on the stops in the pilton rin& sroovea) 1nd phee the eylinde·r over the pilton, (exheust and intake porte to the front) . Gently push down until it ll!ltea wt th the cr-ankeate. Doubl e check that the cyU.nde~ ban sa1ket is ln eontct pod tion and tba c the cyllndet and cyltnder baee bolt. holes au lined up. If you h1ve to l:Otate the eyUndor to line ' up tbe holts double check the c~ank case gaske t again.

S) Phct the coppet' vube.rs over tbto erank!Caee Allen type hex screws and drop into their reapeeth• holes tbrougb the cyUn:let' f\na and tishten teeurely with StntD Allen eype key.

6) Route th& crankshaft a few tl.met and lUke sllt'e tverytbing is cor-rect.l.y u .. mbled thtn lightly ar•••• th• cylinder head gasket both •1de8, pl•ce it on the eylind•~ Dead lirilfi& Up tb~ boles corTectty.

7) Line up cyl1nder hud on the cylinder al'ld tc:rev the eyUndet htld bolta in place -tighten tecurely vltb 5 mm Allen type k•ey.

Pogt20

SERVICE MANUAL CHAINS - c.w:' REPLACtKM

NO SPECIAL TOOLS 1\EQUiliED

The C1~1 uatl cvo al~•• of ebain• and the ltnatba di!fe~ aceordios to tbe eodel. !lOT£ A) Tho podo1Uns c~\a \a olzo 1/2" x 1/8"

I<OfE I) Tho IOOtOT cbo\n \a 1/2" X 3/16" bony duty type

1) The llft of a chain depends entirety on the Cltt and atte~tlon it ••••l••• tnd l! properly cleaned, lubtlcttod tnd tenolontd lt ortlt $11etfon ltl function for many )'tau.

2) A nev cbeln taUe a ltttlt tiM to "'run tn•• and dvrlns this time will netd adjuttlns. Besular ctre end tttentlon 11 required for e~posed chllne 11 Ulecl on tbe Cady. Correct ldjUit:ment h determined by the dea~•• of up tnd down •ovesent (deflection) of tach cheln at e point mtdwet between tbt sprockete, see Fig. 21-1. The maxlmu~ deflection h 1 /2" end the but operating tendon ia t dttltction of 1/4 .. mt.nlmu. to 1/2 .. maxlmuro. See tpt:chl adjuetount for uehlnta W'itb reer tuapenalon on pe&e 26, items 8 and 9.

3) A chain thlt h too loose aay not only ju•p tht aprock.eta but w-111 vhlp aldevaya caulina; exceaaive IP'COOket vear. A ••atrttehe4•• et.in h aoutelly a Vorn cbdn and should be replaced before it wears t-he •vroekeu.

4) Tht pedalllns cb.tns on tbe C.c!y'a n·e provlded vl tb ehaln ten.toners. ~ELS Wlnt nn· aw:penalou have a aprtna load" t•a.lloner wbt.cb ketpa tht ttnlioG const-ant. ~OOEI.S WITHOUT nar autpe.otion han ao adjuateble ttoeloner vb.t.cb vtll require occasional adjuacaent. Set ~•• 2~.

5) To d•ttr.lnt vben ~ chain needs repl1clnc ataeurt 23 p1tchts, ••• Fls• 21-2 (Tb11 would be ll-tj2•• on 1 ntv chain) ancl if tbU h aort than U-3/4 .. replace the- chain.

6) ~ake turt vhtn fittin& a new cbain that tht conntctlns link 1a the con•ct way round. The closed end of the lpt:ina c11p facin1 the direction of ohtin travel. Set Pta. 21-3.

7) Illuetrattonl F1&• 21~ and 21-S thov tht rtNoval ot rlveta •nd f1tt1ns of tht aprin& clip on 1 .. ater 1\nk.

~ fig,21-3

F\g.21-4

Cad ... , SERVICE MANUAL PU1.L£Y CONVERTER REMOVAL AND SEftVlCINC

NO'I'lo ALL PAR'IS li<DICA'IED BY LET1'D! REF&ft TO FIC 22-2 NO SPECIAL TOOLS 1!£!!Ullt£D ltMI pulley eonve-rur ia used to en&aa• or dhe:nsase the -.otor and this h achieved by turntna Ute drht 181ector lever Fl&o 22 ... \ tntlcloc'kv1Jt to the ·~• position to dlaenaa&e the HtOt' and Clodntlee to the ,.K" position to encase the: aotor. Ther• asy be ec..e r ·ealat.ance felt l.n turnlft& the lever to the enaa&ed poaltlon and tbla ll ually oorercoee br l"'llins the •cbiM beckvercSe allov\ns the .. chenl•• to fully ens•se· TM pulley con•erter requi-re a very U ttle .. rvict and the reaov·al .rtd nfl ttt.na are qul te ataple. Moat eervt.ce proble•• are due to dama&• and OT tack of lubrica tion. to terYlce proceed •• foll~ ... 1} f\eaove the drive belt a• described on pas• 8 . 2) Jl;t.ovt the L.H. Chain eovtr tnd the L.H. CTenk cott-er ptn and pedll orenk vi th pedal.

Hold a solid steel object agt1ntt the cr1nk vhen ety1klns the pin to re•ove tt. 3) Ulins aulti-loc:k pll.et:a g-rip tbt duet Clp ''A" end tt11ove vith a twi.at •nd pull action.

4) Rt111ove the clrelip "B" and Vltbet "C" and •Hde the pulley converter off tht pedal Jhlft.

5) Reaove che t v o piece needle b .. rlns ''1)'' - 1.ntptct the pulley hub "f'' and burins• ror veer end or cor~oeton. H•ke au~• the be1r1ns• ert well sreased vith &tneTal purpoet rr••••·

6) CMclt the •otor eos:asement lever •• C" tntl entvre the rivet "'H"' h eecun tnd the tn&l&lnt: "do&" "J .. h not warn. If the dvet 11 10011 lt c•n be pei.ne-d over tt point "X". I( the .-naaaina lever h worn., drill out tbe ri.'fl!t at po\nt "'X'' (5/16" drlll) 10 V31eber "'1." h !ret then punch out the dnt ''H... ltephce t.bt nqu'lred plttl end .. cUTely peia over tbe rlvet et polnt ~··.

G --

n,. 22-2 _ ..

Psgp23

SERVICE MANUAL PULLEY CONVERTER REFITTING & SERVICING AND DRIVE SELECTOR LEVER

NOTE• ALL PARTS I~1liCATED BY LETTERS REFER TO nc. 23- 2 NO SPECIAL TOOLS REQUIRED

1) 'the selector lever '"M" can be nplaced by drilling out the rivet ''N '' fros back of pulley and removtntt; the sc'teW' •tp••. When replact.n& the sc-rew '"P" apply Locktl tl! Slut to tbt thread a fir at.

2) Qeverse the proceedu~es l to 5 on page 22 to ~e~assemble and refit the pulley converter.

3) When replac\ng the crank cotter pin rotate the ped1l axle so the cutavay section facti to the rear, place the crank arm over the axle with it alto !acing the rear, tee Fis . 23-1. Insert the cotter pin ft'O .. the bottotD with tbe flat portion lined up 'With the cutaway port1on on the axl• - put on the wuher and nut and tap into place and tishun nut, route the axle so the crank h vertica l 1nd wi.tb t vrepch on the nut vitb pressu1=e applied strike the twtad of the cotter pin and take up the alack on tbe nut. a t the same time. Repeat thts a few times un~tl you feel the pin is in aa faT as it will so and the nut t • tight . ~ use excessive force when tightening the nut at tbia will weaken or strip the threade.

4)

~~R drive the pin in with excess hammerln&. ALWAYS ceke up the stack on ~be cotter pin nut at the tame time as you ttrtke the cotter plo head . Wben fitting the R.H. crank aTm follow the same ~roceedure as in 3) above . crank arms Left or Right must fact to tbe rear when installing crank cotter the pin is inserted from below and the nut screwed on from above.

Ftg. 23-1

Tho pins and

rl&o 23-2

SERVICE MANUAL SMALL Ellcm; SPitOCJCn A~ CHAINiot!EEL REIIOVAL

NO SPECIAL TOOLS REQYIRED 'iart: All p.trts indicated by letters rtftr to Fig. 24-1

l) ~e.avt pulley converter •• dtaerlbe4 on P•&• 22 ltee 1 to 4. 2) Shcktn the rur wheel al dtac-r1bt<1 on Pl&l 28 and 11ft cha1.n off the 1n~e lprocket and

the tmall tnslne tproeket tnd re111ove the veaher ''A" (lt may 1\ave reaained ttuck by sr•••• to tht pulley ecnvtrtor) and tb8 aaoll en&lne oprocktt "B" '11 th Ito n .. dlo burin&• "C" and vaaher ''D".

3) Re110ve tbe et.rcllp .. £ ... and tht chainwheel v1tb axle h now fret to be reaoved fro. tht dshr 'hand sldt of' the rraM tfter you heve slipped the chain ofr t~ chllnvbetl.

&) It \t not neceatary to ~ova the right h1nd crank for normtl sorv!c1ng of the axle. S) To rtflt the chlln.whe•l and nlt -revent the J)l"OCttdvrt above, 1Daklng aure the circlip

6)

u;" and valbeT ·~" are ln plece and llshtly ~aae the axle with • aeneral purpose artaae. It La tLto a sood ldea ~ apply a sr•••• aun to tht are••• nlpp\t at tbt end of the axle atld (Ot'ct'! some &HUe c:hroush to make lvte c:be grealt channel lt not- bloc'ked, before aue•bHns . aefol't r.Uttins the needle burt.na "C .. and rbe •••11 ene,tne aproclitet ''8'' clttn them thol'ou&hly a ad cott tM-• vi th aeneral purpott s;reue.

' ' oc ns. 24-1

SERVICE MANUAL

MODELS WITHOUT REAR SUSPENSION Machine on ITSstand.

P e d a l l i n g CHAIN The engine d't'ive cb.at.n and pedalttns chain can be adjusted 1 n ~ t p e n d e n t l y or ~O&~t~er tt the same time . 1) Slacken the 2 nuts "A" Fig . 25-1 on the chain tenst.o·ner,

press down otl the unstoner ~t'CI aetting the tension .u described on page 21. tishten the tenstoner nuts .

Motor Chain

CHAIN ADJUSl'MENT

2 } Release tile q_uiek release lever on the fra118 under the saddle.

3} Slacken the 2 nuts on the chain tenalone-r (item 1 aboove)

4} Slacken tbe 2 nuts (one each side) 't the base of the frame stays "c .. ns .. 2s-2 .

5) Pull the ~etr vheel backwards until the engine chain is tensioned at described on page 21. Make eure the wheel is ptoperly centered in tbe frame and tighten t.he frame stay nuta "C" riS• 25-2 .

6) Set r.he pedal ch.etn t-ension and tlghUn the tensioner nuts "A" Fig. 25- 1 and lock the q_uick release lever.

~: MODELS WirH OR III1HOUT REAR SUSPENSION Make SU'te the ch.atn cens\.oner is properly aligne-d by rotating tbe pedals backwards, "if ~here ts any·roughness du• to the arm belng bent or uristed minor adjustments cen be made by gently bending and atralghtenlng the eenaloner arm to correct the alignment.

ftg . 25-2


--. A····

Fig. 25-1

SERVICE MANUAL CIIAIN ADJUSTMENT

NO SPECIAL TOOLS REQUIRED HODEL$ W!nt REAR StiSP£NStON - machine on tt•e stand

1 ) The pedallln& chain on th•n 11odels has a sprtng loade-d tenaioner and c~tn tension ta constantly JDaintain&d . the tensionet can be lifted and. locked ln the ''UP" potitlon 4nd released by pressing the eatcb ''D" Fig. 26-Z tnWJrda.

!lotor Chaln 2) The adjusting of the mo tor th1in on models with re•~ suspention should be carried out

vitb th• rear shock absorbers depreued to the posi tion of •n avenge rld.er. Unlen this is done the chain tension vlll be too tlshe when • .rider titt on the machine.

3) Slacken tM: axle nuts "A" Fig. 26-1 and the locll; nuts ''B" Fig. 26-1 on the obaln adjus ters "C" Fis. 26-1 and push the rear vbu·l bec.kva-rds by set"e.v1..ns in the chain ad justers equtlly on both aides until ~he correct tension \s acbi•ved IS described on p1ge 21. Tighten axl& nuts "A" and adjuster lock nuts ••a••.

Fl&• 26-1 Fill· 26-2

Pogo 27

SERVICE MANUAL FRONT lllf£EL REMOVAL & REFITTING

F'RONT \IR£ELS

Hodels without front suspension - machine on its stand

1) SlacKen the axle nuts and out;. of the forks.

"A" Fig. 27-l. Raise ti:MI liM:f!l off the 8round Reverse the proee~<1ure to r-efit the vbeel.

MOdels wi.th ft:ont suspension - m.achtne on tt.l atand


and pull the wheel down

2) Push the brake am "A" 27-2 and release the cable nipple ".& .. Fig. 27-2 tnd cable from the brake arm.

3) Slacken the axle nuu and "uhets "C" Fig. 2'1-2. Raise the wheel off the groond and pull the wheel down and out of the forks . Reverse the p~oceedure to tef1t the wheel making sure the lug ''D" Fig. 27-2 on the brake plate ts engaged in tbe slot "E" Fig. 27-2 on che IL9.Fork end.

4) Mak• sure the ferrule on the ctble outer casing t.s properly installed in the cable stop located inside the fork end at- point "F" f ig. 27-2.

Fig. 27-1 Fig. 27-2

SERVICE MANUAL REAR NI!E£L REMOVAL' RBFITfl~C

~0 SPECIAL TOOLS IIEQU!IlED REAR IIIIEELS !iODELS WITH a£A2. St"SPENStON' ... ••chine on ita lUnd

1) Push the buke u -a ''A" Fla. 28-t forvnd and r•1•••• the cable l'lipple "8" Fil• 28-t with cable frOID bralce aRJ.

2) Shaken the axle nuta "C" Ftg. 28-1 •~d the eh1ln ldjuettr bolts •'!l•• Flg . 28•1 too push tht whtel forward.

3) Puah the cbatn ttnlloner up \nt.o the locked posl tt.on "E" fig. 28-2. 4) Ltft botb e~tn1 off the retr vbeel sprocket• end pull tbe wheel to the rear •nd out of the

fraae slots. S) To rel)laee t:be vbeel revt~le the proeeedure ••Una turt the slot. in the bnkt plate nu o~

th4 lu& on tbe lnaldt or tbt &.H. rear fork juet rorvnd •nd~ alight.ly below tbt bolt at tbe bottoa of tbe thcH:k abtorber. See locadon lncU.ceted bJ' * on rts:. 28-1.

~EFITTI~C - aeverae the proctedure. 6) the wuhe-ra on the axle ao to the outside of the rear fork followed by tM IXlt nuts.

7) 8efore t1ghtenins th• 1:c\e nuu 1djust the •otoT chain •• dtiC'tLbed on pes• 21 end 26 1nd check the pedll chain ttneiontt. Ttshten the axle nut• ••cunly end edjutt the bukea.

Fig. 28•2

SERVICE MANUAL IU!.U WHEEL IUMOVAL A!ID IIEFITTINC

NO SP!CIAL TOOLS BEQtJIBED

RDIOV>.L

1) Pu•h the b.uke ara •A'' rig. 2HA-l forward and rel•••• the ca.b.Le nipple and cable tte" Fiq. 28A-l Crom the brake ara. Slacken the axle nuts •c• Pig. 28A-1. Raise the fra.e and pull the wheel downwarde and out of the frl.lll.e slots.

Z) Slacken the pedal chain tenaioner nuts and bOlt•, litt bOth chains off the rear wheel eprockets and removo the rur Wheel.

REI"l1'TING - Reverse the proeed:ure.

)) The vubers on the .xle 90 to tho outside of the rear !ork followed by the axle nuta. Tignten t.he u.le nuu securely -.nd Mt the chain t.e.nslon •• deacrib4d on page 21 and 2S and aajut t.be bra~te.

4) Kake aure ~ slot in the brake plate •o• f'iq. l8A-2 flU over the luq on t:he inaioe of tho R.R. rr ... tt.ay at: tl\e point indicated by* on Fig. 28A-l.

t«)1"! 1 When refi ttinq rear wheel a at.ake sure the wheel 1e ----e1th4r eide of the tire at the lnaide of the fork•.

properly centred by checktnq the epac• The •race should b.et eq\l&ll on bot.h aides.

SERVICE MANUAL BRAKE AI>JUSTHENT

~OTE I Al.L "BRAKES NO SPECIAL TOOLS R.EQI/fREJ>

Tb.e butc tdjuatme.nt of the brakes ts done at the handlebar bra.kt ltvlt position. take up any thck in t:hl breke cables during the "bteddtns dolm .. of the bnkes 1nd of the br1ke c1bles .

Thia adjustment will ini tla 1 •t-reteh

Bral<e adjustment - roachine an ita 1tand. Enaine eng.a&etlent lever set to "V" (motor dlaengased) posttioo Fit• 22-1 Paee 22. 1) Slacl(tn the locknut "A" Fig. 29-1 on the

respective brake lever. 2) Spin tbe ~heel betns adjusted and screw out

the adjuu~r "8" Flg. 29-1 until the brek:e be&lna to ensese the wheel. Squeeze the brake lever once or rwice - spin th~ wheel again • readjust if neceteary tnd screv up the locknut "A" Pta,. 29-1 . When squ-eed.ns tht b-uke \ever thtre should be app-coxluta tely 1/2 ' ' of free move-ment befo~e braking takes efftct.

r~ont Brake - mOdels wi~hout suspe~sion 3) Additional adjustment i• p~ov1ded on the brake

a t point 'C' F1&• 29-2. 4} Screw in tbe adjuster •a• Pta. 29-1 on the leveL 5) Slacktn off tb~ nut •o• Fi&. 29-2 squeeze

tQgether tbe brakt shoes against tht wheel Tim and pull the brake inneT wire downvaTda by hold1ns wlth pliers and. twiatin8 at the sase tt 111e.

6) Hold the wire in ~hia pot\t1on and tighten nut 'D' Fig. 29-2.

7) Ma~e ftne adjus~nt at detctlbtd ln lte• 2 lbo~e •• ~ont &rake - modtls with f~ont auspeneion 8) Additional adjustment 1s provided on thta brake

at point 'E' Ftc. 29-1. 9) Screv in the adjuster 'B' Ftg. 29-1 on the lever.• 10 ) Slacken t-e squaTt headed bolt on the cable nipple

•r• rtg. 29-3 . 11) Push up on brake •~ 'G' F~g. 29-3 and slide oipple

up as far as poas\ble and tighten the bolt on the cable ntpple . 12) Make ftoe adjust.tMn t •• detcrtbed ln Ltem 2 above.

fl.g . 29-3

rig. 29-l

SERVICE MANUAL BRAKE SERVICING & CUL£ RSPLACEME~T

Replacecent of cables NO SPECIAL TOOLS REQUD..ED

A ~akt cable ehould be repl1ced vben the brake ltwr be cone tlUSshh or •ttff to operate. Thh h uautll' ~aused by "DA."CAGI:'' "'IUftUNC" '1\UST" Olt. ''COPlUSION .. ar a "FB.AYED" Inner Wln. If you Itt rtplacina onlF tbe inner wire on a brekt eakt sure tt la lubrtcated flttt and follow the a1 ueo..nt dlrectlo~a oo page 29 after you hive lntt•lled dbe ~ev virt. If you ott ropltc1na 1 complete cable flnt check the routine of the cablt you •r• cotns ~o yeplace and 1nttall tht ntv c•blt ln exactly the UM route and. follow the edjuttiM:nt dlnctlona on Pill 29 •

Replacement of drum bra~• ltnings. Remove thl \lhttll aa per directions on page 27 6. 28 & 28A.

l) k~move tht axle nu&s and ~sher and SPICtr f~• the ~ake plttt tldt of ~he txle.

2) Ra.ovt tht brake pla~~ and clamp it Ln the v1tt. See ftg.30-1. 3) With • tcrev drtver. lever the brake abotl U9 .nd of! the fixed

pln .. ,. •• rta. 30-1 then push the ahou orr the bt•k• •n c .. ''!" 'E'ia.3o-t w1.th the tptln&•• "c•• fig. lO-t atilt attachtd.

4) S .. 1r a llttlt all purpose grease on the (1~ pln "A" Fla.30-1 and a lev dropl o( oU where the bt1kt ahoe caa pauea throuch t~ plate. Hake aUTe the bra~ •~ operatet freely, ~en you bave the bukt shoe• off.

5) to inttall ncv brake shoes reverse tbe above operatlon ualrt& nev tprlna• v1. th nev shoes. Attach t"- tprlna• to the shoes 11rtt.

NOT£1 front brtkt on modell vtthout front sutpent1on. lf lt 11 found neceaatry to remov. tither tl4t or thlt centlltvtr type twal!.t rron the fork blades it h beat to u .. '" tepect type tool w-1t:h took.tt to looaen the bolt '1>" Fir;. lo-2. Thtl bolt h ucure,y ttshttntd at the factot'y tnd belnA thln, one could eat1ly tttlp the cornert off the hexagon httd with 1 rln~ or open nenc::h.

The bt'tkt thott v1 th ptds can be adju.ted or replaced by ahekentn& the eyt bolt nut ••E"' Fig. l0-2.

n,. 10-1

na. 30-2

I

SERVICE MANUAL HUllS - SERVICING

NO SPECIAL TOOLS REQUIRfll The servt.cl..ng of hubs rel&Ut; to the altles and bearinq$ (Brake .service will be tound on page 30) and the $ame principles apply whethe.r the ~chine is with or without suspension.

An axle se~ consists of a number of vashers •nd spacer• and lOCJ(nuts and conu. When .atrippinq a hUb of it.s oJ<li the ol:ae< iB lihich tlla parts ar• usr..ml>lod should ba earafully notl!d.

1) Remove the wheel and if • drum brake is fitted remove ~e brake plate. See pages 27-28-30. 2) Once the brake plate is removed you can proceed with whatever wheel is involved. in the same a&nner.

3) Grip th• lock nut. oo th.e dde opposite the brake drum in the v-ise and 111ith suitable tool.9, remove the lock nut t ·rc:.. against the cone on the expoted. .side and then remove the cone .

4) The wheel can now be lifted oft the axle - tl'le ba.ll bearings will drop out.

S) Wa.sh ott the hub and the beari.nqs and oones with a suitable solvent and 'fipe dry with a clean raq. Inspect the cups in the hu.b !or any rough •J>Ots, a.l$0 the oa.ll bearings and cones o,ncJ replace aa necessary.

6) Pack the bearinq cups in the hub vith q&nerAl purpo84 qreaae and place the ball bearinqs in tho qrease in each cup.

7) Rasaemble by revers i ng the strippin9 procedure.

NOTE 1) It is alway& advi9able to replace the ball bearinqs vith new ones when servicing a hub. NOTE 2) It you are not sure how many bearings should qo in the hub the best rule to follow is to

fill ~· cup to create a full circle of ball& and then remove one .

8) The final setting of the cone should be done with the wheel in the Vise, sec item 3 above, so that a very slight amount of play can be f"elt. at the rim and with the wheel removed !rom the vile the axle should rotate smoothly between the finqers.

WHtEL SEARING SIZC CHART

MODEL Ml-PR Ml-PRTS M3-PRTS

FRONT l/4" 7/32'· 7/32••

REAR 3/16•• 3/16 .. 3/16 ••

P>ge3t

~SERVICE MANUAL THI<OTTI.£ CAB!.£ JJ>JUSTMENT

NOTE A Machine on ltl ltlckttlnd NO SPECIAL TOOlS REQUIRED

It la importlnt to a llow 1/16" to 1/8'• of play 1.n the tb.rottlt cable to ellow !or 1n7 "pull"' on the c a ble when the tten·ina 11 roc.ted .

1) St1rt the •otOT - 1 llov ~1 .. foT vtr. up and TO~te the ttrrottle notlns the tiiOunt cff rotation required belort the enalne tpeed plcke up .

2) With throttle elot ed unacrev tbt idle adjuat1o& screv 'A' Fts. 32-1 until the enat.ne •peed 11 1 t lea louut t nlt then t lovly .crew lt t.n until t.be enstne ,_,...,s juat btclna to tncnu e.

3) At the lt~r ~nd a ltckt n tnt lock nut 'A' ft.&• 32-2 and vt.tb throttle clow...S t cr•v out tbe t djuat.-r· •a• Fl&• 32-2 untU ttM enaine lpltd i.ncnutt - tcr·ev the adju1ter beck ln t\10 Cull tuna t od tl a.bteo tbe lock nut *A' Pl g. 32-2.

4) You should nov htve the nt CIIItrt .. ount of tree TOt.ltlcm on the wla t srtp be!ort the tnat.ne ""•peed tncreaaea and remove tht pot albltltt of any increase ln enatne t pttd vhtn tht ttttr1n& 1• rotated .

S) Up to th1a point ve ~vt aaau.ed that the th~ottle .tre and ctain& ere ln sood condltlon ao lt la advlaable to open 11-s cloat the thl:ottle 1 rev thM!s and mtkt aurt tvtrythln& 11 ln order.

6) lf the edjulttr h.u to be s crewed out to t.ta ful.l extent refer to Pllt 36 ltt• 7 for tnt truct1ona of add1.tlonal adjuatment It the t wi.a t gl'lp .

7) Should the enain• ,.,.,c1 not elow down to en idle

"' .. 32

a!~r opentlns the Mat &rlP checK the throttle c1ble for damase 1nd rtpltct ll ntctlltry , .. past• 35 and .36 and check t hat tht throttle elide la not stlckln& Itt P•&•• 37-38-39 . Aleo check tbat the ldlt adjusting acrev 'A' F1&• 32-1 la not acnwed tn too hr .

Fll!o 32-2

SERVICE MANUAL CROKE CABLE ADJUSTMENT 4 REPLACEMENT

NOTE "A.. The choke cable adjustment ts simple and seldom NO SPECIAL TOOLS REQUIRED rtqui Nd but like the throttle cable it h t.Giportant to taatnutn tt coT-reetly and opeut1n3 fTeely foT correct eng\ne perfo·r-maoce.

1) The choke levet: h found on the l eft hand lever bracket 01A" Fig. 33-1

2) A saall a~otiftt of free ffioviffi6Bt of the choke leVer !t reqUired and this should not exceed 1{4" at the lever end •

.3) To adjust nut unlock the lock nut ".B" on the adjuster "C .. and adjust until the requit:ed free play ta achieved on the leve-r "A" Fi.S;. 33-t .

4) Check to make sure that the choKe soves freely Up and down. 5) If everythtn,s h tn order tighten tb-t l.cx:k nut 1nd double check the free moveJDent.

6) If the choke sltd& stick$ or is stiff to operltt lt may be nec~esary to replace the choke cable due to damage or n.~st or tbe choke elide could be cor'('oded or datnas:ed .. see pages 37-38-39 fot" "Carbut"ett.o'C Setvtce".

7) l'o replace t.be eboke tnnf!r viTa Slacken the nut "'0" Fig. 33-1 at the lever - Hmove tbe carbunttor from t he int.a,ke oipe and push the lnner vlre dOWTI and pull lt out ft'olll the bottom of the chokt slide.

8) Ligbt-ly lubricate tM replacement w-ire and feed it up through tbe choke slide 1nd the outet cadna until lt app•ars at the lever tnd.

9) Sc:rev the adjustet' all the vay tnt-o the lever bnoket.

10) P1$S the wire through the adjus~r and into the pinch bolt on the choke lever - pull gently on the wire to take up any slack and tig,hten the pinch bolt. Adjust as described above, itemt 2 to 5 .

11) If it is necessary to replace the outer easing, remove the inner v lre fttst and tnst411 the outer eating following the same route as the old one. Then Lnst.a 11 the inner vlre at described above (items 7 to 10).

Fig, 33-1

•

@

,.....,

SERVICE MANUAl DECOHPRESSOR CABLE ADJUSlMENT ' ~EPLAC£HEI'I'

NO SPECIAl. TOOLS REQUIRED

~ dteoaprtaaor cable is fouod on the Ri&ht lltnd lever bracket and it is important thet lt 11 never over adjuated. Adjuataf'nt

1) A taall aaount of free eo ... t-.. nt of tbt dtcoapr.aaor hn·er lt requiTed aDd tbh abould not exceed 1/4" of •ove.ent at tbt lever tnd.

2) To 1dju1t first unlock the lock nut on tht ad4uster and unscTe~ tbt adjutttr vntll the rt~ulred rree play is tcbleved on the ltv.~.

3) Chick to •ake eure the decomp~etsor movtl (rttly up tnd down. 4) rr overythin& is 1n order tighten tht locknut and double check the free eovtmtnt. 5) If t.ht dtoocnprtasor st.icks in the "down" pod tlon vhtn optntins the lever check tht

Clbla for damage and or ruat. To do thh tcrev tile adjuster at the lever all tht VI)' ln end ttmovt tht cable at the deoompTetaor and check that the cable opecate• frtely. If nectlltry ~place it, see items 7 to 10 balov.

6) If thf cable operates freely ptela down end ~•1•••• tbe decomprestor a few tlmet wtth yout thumb *Dd lf it sticks yepbce it, 11e 1tema 11 to 14 below.

Cable Rtplacement 7) tteeove the old c•ble by tirat slae111:en1n& the plneh bolt on tbe lever an:S pullln8 tt. lnnu

vlr. out then ~ve the nipple f~ lta holder at the cylinder bead - then the coaplete C:tble. 'iote the' shouldered ferrule poaltt.on ln tbe top plate on tbe decotpreaaor.

8) tte-route the nev cable throuch the plaatlc caalna and reverse tbe p~eedure ln lte• 7 above, aak1nc au:re the shouldered ferrule h properly lit.tt>d tcc.o tbe cop plate on the d•ca.pnasor.

9) Before feedlnc the lnner vtre lnto the lever pinch bolt, acrew the cable adjuater on the lever bncket out aboue 1/4,. then talte up the sleek on tbl!! lnner wi.t'e and tishten the ptnc:h bolt.

10) Make flnal edjusteent as described above tte•• 1,2 ' l. Dteomprtllor rtplaetmene 11) Removt ti'HJ cable ·disconnect the plus lted. 12) Remove the upper engine mounting bolt, tour Allen type cylinder he1d bolts end tht cyHnder head. lS) Remove the dtcompressor valve usin8 e vrtneh on the hexagon nut on top of tht velvt 1ttm 1nd a

Ierew driver at tbe base of tbt valve tttm 1ne\de the cylinder head. 14) Jnltall the nev decompreasor revera1n& tbt ebove proceedure, ao4 ust 1 new he1d gaaket.

SERVICE MANUAL CABLE ~EPI.ACtME!IT lllliOTTU

~0 SPECIAL TOOlS UQI.'J~ED liOT£ ''A'' Quite often lt ts pouible to r:ephc;e only ttle t.nntr vire rat-her than the complete aaaembly.

but thlt thould only be done tr the outer easlna lt tn good eondttlon. Th~ 1reas moat 1ubjtct tO dam•&• are the expottd ltcttona of the cable between the control end the fralle.

Th-rottle

1) Sbcken t.hl locltnut "A .. f1.s. 35-l on tbe cable adjuater "8" fl.g. :35-1 and tc::ttw the edjvner into the tvist grip bracket u far as potalblt.

2) Unscrew the tquart headed cable ntalnlna bolt "C''" Fla. 35-1 pull out throttle cable .

l ) Rea:ove the carburtttor from the intake pipe by slackenlna the clamp '"E" Fla .. 35-2 10d r~ve the acttv '1J'' N.s. 35-2 on the elrlns cha111ber cover ''F'" N.s. 35-2 •~ ttlt eowr coeplett vltb tbe throttle a11.de and spdne and choke slide and tpd.na,aee Fig . lS-3.

4) Push the throttle inner wire down 10 you can pun Lt. d&ht out of the throttle sUde and thrott1t alt.de spring. (Some carbunttora b.ave a ph•tte: ctble gvidtt c>n the mhtng cha~ber cap - th11 vlll become !r11 when the inner virt 11 rmoved, so phc:l it aside until tnatalltn& the new inner wire or coeplttl cable) See ftC" Fla. 35~2 •

,

C: -~:' ~ A B

•

F! r,. 35-3 Flr,. 35-l

Fl&· 35-2

Conttnued on nex~ paee ,.35

SERVICE MANUAL CABLE REPLACEMENT tHROTTLE (Continued )

See Page 35 for F1&· 35-1, 2 and 3

5) If t ·ephcint only the inner wire feed tt th'tough the mixing cbu,bet CiiP and plastic cable guide (if used) and through the outer caatns, leaving enough wlrt to replace the spring 1nd the throttle slide . Now pusb the tnne~ wire up to the point where tbe sp~ing is held betveen the cap and throttle slide.

6) .8et'ore installing the throttle slide ''K" Fig. 35-2 and chol<e tUde "L .. fig. 35-2, into the aixtns chamber, Une up the slot ''H" Fl&• 35 .. 3 in the throttle slide lfith tbtt small guide pin .. J" Fig. 35- 3 inside tM mixing cb.amber (th., cutaway portion on the bottom of the tbrottle tllde facing the alr filter}. When lined up pToperly push che throttle and choke slides into the mixing chamber, see Fig. 35-3. Correctly lined up they will slid• in •asily. Now, press down on the cap compreaaing the tpring.s and replace the tcrew "D" fig. 3S-1.

1) At the twist gdp end you can now feed the tnne1: wire thtougb tbe adjuster and into the reuiner with the .square hu<ted bolt "C" Fis. 35-1, page 35. Full up tht slack on tbe inner vtre and tighten the squ$re headed ~etainer bolt.

6) B-efore rtf1ttlng the carbu1:ettor to the intake pipe, operate tbe twist grip a fell times to ensure the throttle is vorktng freely.

9) Refit the carburettor aruS make final adjustMnts as dea<::ribed on pagt 32.

10) To replace the complete cable follow the tnstructi.ons 1 to 4 on page 35 and then uparate the new inner wire from its outer casing.

11) 6efore removing tbe old outer cutng observe the route it. follOW"& arxl then replace lt wteh the new one .

12) To complete the operation once the new oucer casing ls installed follow the instructions 5 through 9, above.

SERVICE MANUAL CARBURETTOR SERVICE

NO SPECIAL TOOLS REQilll\EO SOTE "A" 1'he Cady cnb\n:'ettor h a very atepb carburettor and is 1 s:r:avity feed ~ype,

NOTE .. B" In the- tv~nt of 1 carburation problem and befoTe decidtn8 that: it 1• neceu1ry to t:eDOve the cat:buNttor, first ctt.ck tbJt there ts fuel flowing {roc tbe fuel tank to the enbl.n:ettor.

TO CHECK FOR fUEL FLOW 1) Make •ute there is fuel in the fuel t3nk and with fuel tap up (OFF), remove the !vel line from the

fuel tap, push the fuel tap down {OS) and make sure tbe fuel is flowing . If tbe fuel is flowing pull the fuel tap up (OfF) and refit. the fuel line , Re.pea.t. the processes at the carburet tor to ensure the fuel \s flowing.

2) There ere two filters which should be checked . On~ is s1tuat&d on the f\lel tap ret.atnint bolt "A" Ftg,. 37-l. The other is on tbt earburettot at the float bowl cover "8" Fls . 38-2. If there is a lack of fuel to the cu:burettor tb~ flltets could be blocked or tbe fuel line closged .

FlfEL FILTERS

3)

4)

5)

6)

To check the fuel tank filter reeove the fuel up retaining bolt "A" Ftg. 37-t and check and clean the fUter screen. To check the earburettor filter remov~ the slot~ end cap "C" Fts. 37-2, pull out the fllttr, ch~e-k and c lean 1 t. lf either filter is damast4 replace tt vith a new one.

Make sure the saskets on both t he fuel tap and carburettor lntake are in good condition - replace 1 r necessary ..

7) With the filters and fuel l ine back ln position re•ove the jet '"D'' Fig. 37-3, pusb the fuel tap d.o\m (ON) tnd fuel tbould TUn out of the carburet~or.

fit. 37-1

c

Thh det•m1nes that fuel 1.& reacht.ns the float bcnro'l '"E" Flt• 37-j. Replaca the jet after cleaning thorOU&hly.

flg. 37-3

continued on Pagel 38 & 39. ,.31

SERVICE MANUAL CAR8URETTOR SERVICE (Continued)

THE FLOAT

8) the float bowl contains a cyllnd~ieal float Yhieh inco~porates a needle tbroush ltl cente~ . As the float bo~l fil ls with fvel thP. float rtses and at the correct fuel level the needle seats into tbe inlet valve and cute off the supply of fuel.

9) If a situation of fuel flooding occurs it could be due to tbe needle ~ot seattns correctly for the followtn& T~•sons .

a) The needle teat has so~ foreign m&tte~ in it. (Crtt or gum oll)

b) The float needle ts bent (uncommon) o~ worn (common after long use)

c) The floa t ttas a leak ln t t and fuel has entered and made it heavy (uncommon) .

10) To check any of the si tua tiona A, 8 or C remove the t:vo ae-rewa "E .. fig. 38-1 anc1 remove the float bowl cover .. J" and lift out the ftott "F". Check tbe need le sut for any foreign matter or gum and etean 1~ thoroughly . Check the needle and make sure it. ts no c. bent or worn, tee diagram Fig. 38-2. If bent or worn replac~ it with a new one. Shake the float to determine if there ts any fuel tnstde and if ~o replace 1t.

11) Check the guket '"C" rtg. 38-1 on the float bo-wl coveY and replace if nece4sary.

12) If the needle ta lO'Orn the needle seat ln the float bowl cover will also be VOTn and it also should be replaced along wi tb tbe float.

13) The other things to check if there is a fuel leak is -a) The fuel tap is ttgbt b) The fuel line is not cracke4 or spltt.

Fig . 38-l

Fig . 38-2

14) Before replact.ns the float and float chamber cover inspect the t.nslde of r.:he float bowl and clean it out thoroughly. There could be gummed oil and grit inside or water or corrosion caused by moisture .

AIR FI ~T£1\S lS) There a"t"e fine wire mesh scr~ens in the air filter "W' Fig. 38-l which should be cleaned ; thls

is ••$lly done by removing the atr fl\ter eov•r and r~mov1ns the two sere~• on the end cap of the air filter, sivtng access to the s~reens. Wash these clean with a sutteble solvent.

P:fge 38 Continued on Pagt 39.

SERVICE MANUAL CARIIUIIETTOa SEllvtCE (<ontinuod)

1llllat"TL£ ' OIOKE SL mt 16) tr the thtot.tle or cho'kt tn atlcking follo-e tht lnt tTuctl.ont on PISI 33 tor choke.

pes•• lS and l6 for throttle, and 1napect for 1) Corro.ston e1uted by molttvrt b) Dt~~ase to throttle tltd• and o-r cb.okt aHde e) Frtyed thTOttle or choke wires. d) Throttle oY choke ~lttl at!ff tn outer C11ln6•

To co~ect the above proble•• e) clean the throttle end choke slides ~boroushly , 1110 the in.ide of carburettor

a1xlnc ch1aber - i.nltrt ucb of thea~ tndivl.duatly into their ntpectlvt polition to aau aurt 'ht7 operate fnely . !bit c1n be done vlth-o\lt reoovins t.ht alldu (r.. the inner vina.

b) Daus• to the tht"ottlt alldt and OT choke tllde h utually in tlM' for. o! • burr . lt tuy be ~alble to rt~ve thb \lslnc flnt vet tnd d-r-y rubbins dovn piper. After rsovin& the ''butt" check each alide 1n tu reapec: dve poatdon and ••kt ture they op•nt:e freely. If ln doubt Ot' t.f damased too much nplac:e the p.ttt.

c &t d) Replace any frayed wt.ret and or outer caat.nsa, Itt Pl8t 33 for Choke Cable or ptses 3S and ~6 for Throttle Cable .

17) After aerv1ctns a catbutttto~ and before intt.111n8 on tbe englne , double check th1t the throttle 1Dd cho'k:• •Udtl operate freely end set tht ldlt tcl'ew. n. be~t way to do thia h to UNCTev the ldl• tc~ew to allow tht throttle tUde to be ln lta lowest potitlon • tMn acrtv ~· idle screw 1n tlovly until the throttle tlidt be&1na to rln (Tbls can ba oNU'Ved by looking into the cnburtttor air lnt.ake v1. th tht air fllttr rtaoved). Se• al.a Pll• 32 for tdle adjust.eot.

\S) flntl ldle adjua~nt. Ctft be .. de after the carburettor lt atseabled on the tnatne and vitb the ensint nm:n.lr!a.

Co-d..c/ SERVICE MANUAL PEDAL 1\E!tOVAL AND R£PLACEl!E!IT

MO SPECIAL TOOts RI:QIJIBED

NOTE Ae The pedala 11 ua•d on Cady mopedl uae a metric thread (14 .. ) and lt it lmport1nt that the oonect replaceg,e ntt art uted .

NOTE Be A pair of p41d11l consht.t: of one 'Rlsht band and one Let't hind. The R.ls,ht htnd pedal c1n be 1dent1t1ed by letter 'ta." or ''D .. aumped on the thnaded e.nd or 1houl.der of tbe !>f4al optndlo. Tho thread ts rl&ht hand and 11 acroved lnto the pedal crank clockvtoe aM Hte on the dabt h.nd aide of the .. chine. lbt Left hand pedal can be ldentlfied by tbe letter .. L .. ot ''C11 acaaped on tbe threa<led end or ehoulder of tbe pedal ah1ft. The thread 1a lett hand and b acrew.cl lnto the pedal crank tntlclockwise.

1) To remove the pe<hlt \Ill a pedal vrenoh (epprox 13 .. lons) to eahleve aufflclent leftrase. Fit the vr:ench over the nau on the end or tbe pedal •plndle and unscrew tutnins the wnnch anticlocktirlU for the Ri&ht hand pedel and clookvilt for the Left. hand pedel.

2) To replace tht pedeh elvaye "st.llrt"1 the tbreade usin& yout' flnaerl, mald . .na aurt th pedal spindle thr .. d• are lined up corNctly vi.tb the pedll crenk tbreade. Thh wlll ell•lru•te erou tbreldlna.

3) Serev the pedal I'J)lndlte ln all the way ancS tiahten aec:urelr vt.th the pedal wrench.

4) I! a lon& ptd1l vrench 11 not avall1ble u1e a auit•ble open ended WTencb and a lenath of ~tpe tG extend the lenstb and obta1n the necessary ltvttl8t to tither T••ove or r.pl1ee the pedele.

PEDAL WRENCII

SERVICE MANUAL !tEAR FORK REMOVAL & REFITTING & SHOCK AIISOIII!ERS

Modtll vlth rear suspenaion IWIOVAL

1) kt~e both chain covers 2) ae.ove rear wheel, see past 28

3) ~••ov• puller co~er~r. ••• past 22 .

~0 SPECIAL 100LS REQUlltED

4) Reao~e .. all engine sproc~et and rl&ht ~nd chaln wheel vi~h axle , I tt paae 24 , S) R•.av• tile lower shock abtorber tn1tt .. A'' F113. 41-t (both aides)

6) Re~• tbe 2 chaln tenstoner reu1nLn8 boltt "8 .. F1.8• 41-1 and the chaln ttnli.Ofltr pullet bolt and pulley wheel "C'' Fig . ~1-1 and the chlin tendoner is now ftee to be t'•ov•d ftOIU tht ptdallLns ohatn .

7) Re•ove the rear fork pl~ot bolt and nut ' 'D'' Ftg. 4\-2 and pull the rear fork out of the frame .

8) Rtplacttotnt reu· forks t'te fttted vtth pivot buahtl Jrd retdy to be tnstJlled.

REFI'rt'INC 9) To lftltall the rear fork revene the 1bovt OJMtttiont ma.kln& sure to S,TUte tht pivot bolt •1>''

F1&• 41-2 vith pnertl put'pole &TtUt end .. c:urety t1&hten the nut. !'fake IUTt tht ~allln& c:haln tnd -.otor cbaln are inside the ahoek •horbera 'before refitting the loutr ahoek abaorbtr bolu.

10) The r••r foTk bushel ~r• replactablt. but thls ehould oot be atteepted uoleaa a vr••• 11 avetleble .

Ftg. 41- 1

,.,. .,

SERVICE MANUAL P.EHOVAL Alill REFITTING OF SHOCK ABSCR6£RS

The Rear Shock Absorber•

Theat are a f•etory aat .. bled unlt and oot 4ea1tr.ed for repalr tnd ahould ~ repllctd 11 a eoaplete aat .. blf or 1n palrs . If replaelna one abock ablorber only, lt vill be necessary to reeove both ahock abeorbert froe the aachtne tnd check the nev one for tenath t81lntt the on@ to be retetned. If tbere h 1/2" or aore difference vhtn extended replace both thock tbaor~r•. Thlo will eneure equal eomprtttlon of tht lho¢~ tbtorbotl Uhllt riding •• ve\1 11 correct autpenaton .

Retaovtl NOTE 1 the rear shock al>eorbeu are ret.tned by bolts and auu It the top

and bott011 of each vnh, See Flg . 42-1 "A" and '"I". Thrt lower bolt aaanbly "I'" h threaded lnto tM reer forlta and tocltt!d with. a loek nut. The upper bolt aaanbly paeatt tbrousb a bole ln the traae brac~et .. C .. tnd 1a lock~d with \.tl nut •t point "A'• f1S• 42-t.

1) Rtao~ tbe nut !ro• lnst.dt the rtar fork then unacuw t he bolt ••!" makln& • note of tbe order of wtabera and spacer.

2) Remove tht bolt .. A" and nut Crom the upper fra11e bt'lek•t·

3) Rtmovo the shock 1bsoTbet".

Ref\ ttlnA 4} Rtvtne the lbo,te proceedurt .. tM 1p1cer e;oes between the fr-a~~e and

thock. absorber on the lO'N'r .ounting bolts ..

5) Mlkt turt tt. lover bolt h e.curtly tighten-' into tht t'tar forka and tbe nut locked up tl&ht. Alao the u-pper nut •nd bolt ere IICU'f•ly tls:bteoed •

NO SPECIAL TOOlS REQUIB£0

Fla. 42-1

SERVICE MANUAL FROST FORK Rfi>IOVAL AND REFITTING Hodel• vttbout ft"ont eutpentlon - ~•chtne oc its tttnd NO SPECIAL TOOLS R&QUII!.ED

l~VAL - ~oe. : If ~vtns on11 to service the head flttins• th4 front vbeel and audau•~ ctn reaaln ln the forks.

1) Remove the btndlebar numbly complete wit.h tUm and control levers by unsert'win& tbe bolt "A" Ftg . 43-1 approx. 1/4'" and Upptnt it down to ~•ltill the expender p1us \oca ted inside the fork column at base of the stem . Lift out the handltbn- assembly and let lt hang to ON! a1de.

2) Reaove the front wheel, Jet ~~· 27 and support the 111ch\ne with a block under the atUf fltr.

3) fhtaove tbe .OOsu•l:d atucl'w!d by 2 bolta aDd nuta u. f'orlt c-rown a!ld 2 stay eye bo\ta ju.t 1bove for• ends.

4) Slacken tbe pinch bolt nut "&'' FiS• 43-2 and pull out the bnke wire.

S) Pe•ove t~ head flttinK• C & D Fig . 43-2 tbtn tht 11~ br.•cket vith heed ltmp and born and let it hans to one lide, then the ttasber and t~ lcreved 'tiCI "I'' F1S• 43-3. f!old tbe fot'kl vhilt untcnvin& the tcrtwed nee end Vhtn fo'(k ls ftee it <:an bt puthd down and out of the fume. TIM loose ball bearinsa (S/32") wt.tl hll out from t he bottom fnm• eup "C" Ft&. 43-3 and can be removed fr0111 the top cup "p•• Fi6• 43-3. theet thould be t"ephctd (24 b•ll• to ucb cup) when aervic! ns the (orke.

6) [f ftttlnc a nev fork the fixed cone ''H'' Fl1. 43•3 ctn be reaaove<l by drhlns lt upwar<ll hoe underneath, u'ins a ht_.r end puneb tnd then refitted ooto tbe nev fo-rk. Ddve lt on utlns 1 brett or copper punch ao 11 not co d••a~ me be arias aurf•c•.

7) &.fore refltt1.n& the for'ka check =he btarlns aurf•ce• or the pettl "i"', "H", "T"' 4 O.C", f1g. 43-3. The•• paru ahquld tll ht•• 1100~ btorlns aur,acea ood lf ~om be up heed . The fuM cupa ••r•• ' "C" can be u.oved utt.n& a punch and hatmllr - vben 't'tftttln& them uae • h1l'd1tood block..

R£FITTTNC

8) Before r•fttttns the forkl revet"stn8 the ebove proceedure, p1ck tbe top 1nd bottoe fume cup "F .. & "C" rl,. &3-3 vt.~h sener~l purpose &Telel 1nd place the ball beatlnaa tn tbe srease.

Fl5. 43-1

na. 43-2

-·3

SERVICE MANUAL FRONT fOIU( 1\EMOVAL AND l\EFITTINC

Models with front suspension - Machine on s~and NO SPEC! A L TOOLS 1\EQUil\ED

l\EHOVAL

Nocet If recnovt.ns only to nrvice the head fitt1ngs, tbe ft;Ont wheel and mudguard can remain in the fo'l'l<S.

1) Remove tho handltblt uoembly complete rtth control loveu, by nmov1ns the nYU ftom tbe handleba"t" ''U" bolts, ae:~ "A" Fig. 44-1 and on some 'models remove the bolt thOJt loelc;s t.be handl•barl (i t ts ln front of and between the two ''\I" bolts).

2) Remove ~he front wheel, eee pag~ 27 and support the =•chine lrlth a bloc'k under t-he muffler.

3) Resove the IIUdguard by umoving the stay fixtng bolts, "C" Fig . ll4-2.

4) Disconnect the horn wire& and the ground wire located at the back of the ntadlamp movntina plate 'T" Fig. 44-3 then remove the tvo bolts, one on each side (left ard ctght) of the he3dhmp mounting plata~, see "C" fis . 44-3. RefoTe you can remove the head hmp completely you wilt hJve to ~tr•ighten out a me~al tab th•~ secures the he1dlamp body to the fork top plate, loca ted centrally between the fork less. Th1h is reached fTom the back of lind from underne1th the headlamp and stTai.ghtened. out by levering with a SCTewdriver . Let tbe headlamp hang to one side.

5) Remove the fork stem retaining bolt "D" fig . 44•3 by fitst bendin,s batk the t.al) of the lock washer "E" Ftg. 44-3 then reiDove t-be head lock nut and its washer. Se& "1\" Fig. 4S-1 on p.Jg$ 4S.

Fig. 44-1 Fia . 44-2 Fig. 44-3

Contt.nued on next p.age

SERVICE MANUAL FRONT FORX RD40VAL AI!D kEriTTINC

REMOVAL ( continued )

6) 't'he for)t a.saelll)1y can now be ramv.S, see Plq. cs-2, ~inq a ba.rc!wood block and a"'---'"· Thh will apr1nq the lowe.r pU\t.e ott t.he botto. of fork ate:ca and by pullin9 the fork asaubly forward and up, it will Uft off the threaded upper part ot the fork stem. "H" Fiq. 45-2.

7) The fork sua ''H"' Fts. 45-1 ean nov be rt110?e4 by una crtrlD& the acrewd ·uc:e "J .. Fi&• 45-1. Tllo looH boll b .. dn&O (5/l2") vi\1 foil oUt of tbt 'bott .. !TIN cup "L" fl&• 45-1 and Ol D b4t TtiDOved h'o111 the top (nM: cup "'It" ria. 45i-1. the .. ahould btl repbctd (26 b•l.l• to each cup), when aervlc1ng the forkt.

REFITTIIIC

Note "A" Before tef1t;.:1n& the forD check tbC! bearlne; aurleees of tht PICU J .X.L •nd H, au ris. 45-1 . Thue paru ehould all have 811ooth beulna eu-rfacu 1nd l f worn be rephctd. The fr1me cup1 "K .. •nd .. L" FiS · 45-1 c•n btl t:tmoved ulln& 1 punch 1nd hammer - when r.ftttlns tt'Mom uae a h.a~vood bloc.k .

~ot.e "I" h!ort nflt.tlns the Cortt1 t'eversins the removal proc.e<!Vt'e, pa-c:ll. the top and bott• fnme CUPS •"K'' and ''L" fi&• 65•1 vl. th geneul purpose STUSt and place thot b11l beadn11 in the snue.

:Nott ··c., Tb~ fork useably hat to be aprung back onto the for'k st.ea, eftet the stem hu been lnttalled tnd the .screwed ·nee ildjUtted so the atea rotates freely and there h no up and do"" p La 1 •

Note ''D" Rotate tht fo-rk etem ao the chtmfered edse of the !lxed cone at the bottOUJ of the fork atem r.cu the- front of tht mac:bt ne and the t wo lugs in the hole in the loW'er plate art in line v1th the correapondina sroovea 1t the bast of the fork t tem .

n 1 • 45-l Flg. 45-2

SERVICE MANUAL HOOELS WlTH FlO!IT SUSPENSION

Note1 In ao1t tntt.oce• tbe fo~ka can be aervlced ;t'he atchlne. To do tbi• n.o•• tht front wheel, see P•&• 26 tnd the front a...Ssu•rd , see PIC.t 44. (f lt lt MCtlllt'Y to r~VI t.be CC*pltU fOTk, rtfer to pasea 44 and 4S. In tny event tbe fotlovtna lnttTuctlont apply. TO DISASSEHIL£

1) Eltbtr Cork blade A or 8, Ftg . 46-1 etn be ~•moved by untc·rewlnt the alott.ed nut.-eetal cover ard rub~r vuht'C "C" Flt, 46-2 vhieb tltCNI the COIDplttt fork blade A or 8, with spring "C .. Ft.g. 46-3 11'1d. upper tpr1n8 uutner '"F" Fig. 46-1 to be COIIPhtely reaoved !tom the fork tu~ . thls ataeebly can be e~pattted t1tup1y by uns c-r:ewtng the fork bhdt or t.he upper tpr1ng retainer from the aprl.ng.

2) TM fork bhde aeals "D" fi.& • 46-S can be naoved by unterewl.na thttQ (usually by ~nd) ft:OII the fork tube after u.1aoving the fork gator '"£" Fie . 46 ... 5.

l) In•ldt tach fork tube 11 a se~ of bu1b11 and el••~~• te• ""H'' Fta. 46-4. These can be re:r10ved and replaced lf vorn but thi1 11 ttl4oe neeettary.

TO REASSEHIIZ

4) Rever .. the above proceedure replaclna the bu1b11 and tletvtt ln ordtr at lllusttated anJ co1tln.a tht lprlns• vttb srapblted grease.

S) The eprlnst thould always be replaced 10 fork endt are equalized ln ltnsth. •lx old and new aprtnss.

ln pllrl KEVER

6) M1kt tute the fork blade• ne fitted to the correct tlde. The main difference 11 the R.H. fotk blade hae a slot in the fo~k end to rttaln the bukt plate, ••• * Fig. 46-5.

FlO~"T fORK SERVICING

NO SPECIAL TOOlS REQUIRED

F

A

• •

Flg. 46-3

G I

<l'>

na. 46-2

SERVICE MANUAL FO!Il LOC1C ntSTALI.ITION AND IU:MOVAL

KO SPECIAL TOOI.S REQUIRED

If a forit lock tt.t to ~ lnsulled or neovM follo" tht inttruetl.ont be1ov. ~ loc) asst•bly cons\Jtt of 5 p\ecea and ~he7 ete 1nst,lltd \n the order at ,\sted.

"A" .1 splh washer "8" a sprins "C'' tht' buu lock "D.. two keya ''£" a vir• clip

Tht> princlple is to lock the lteer.l ng so th,. machine cannot l)f dttvfn or Vhf'eled away.

~ote1 The lock housins lt located C'ln the left side at the ten of the lteedns hea<l jutt above th• ruel tank. 1} Place tht: split washf"r overt:~ "tongue" of the br-ass lock, partially insert th~ loek tnto

the housln8 and coap~••• the split rln& so it enters the houstnc. intert • key into the lock aod wrn h tnd-cl~kvt se and puth the loclt ln as far a a possiblf' . This vi 11 pbce the apll t washer into lts p-osition inside the housins .

2) With the key still inaerted and r.urn4!d to th~ left (antl. .. clockwise ) remove t he bun lock end place th, apdng ovu· the "tonsue•• and still W'l t:h tbe key turned to the left 11'1ert the lo~k vitb t~ tpt\ng in plece into t~ houslns •• far •• it will so.

3) Release the key so it turns back to l.ts vertlcel 90Sition end it is lnatelled. f1) To secutf> it in phee vlth the vlre cllp. The: t:wo short end• of tho clip lit into the holes

(one •ither tl.dto) provided t.n the top of the lock housina 1nd the clol~fJ end of' the. clip it snap~ down over t~ front of the housins.

5) To loclt tM forts turn the key to tht left hntl-c:loekvit•) pressln& the brut lock lnv1r<11 at the SIM tlM and rotate the forks to • riiBht turn posit1.on and eave tlic,htly to left and rl«ht while stU I •pplyin~ i1'watd p-rellun to the lock. At the correct position the lock will IIH)Vt ln a Uttlt further u tl1e"tonRu~" fits into ite slot in th~ fotk atH~.

6) ih~ key een now be reMov~ by turnln8 it clockvlse to 1 v!rtical poaltton. 1l ~o unloek the for\ lnstrt the ktJ anrt turn lt to tbt ltft (t~ lttoekvla• >· The spring vl11 puah

th~ lock out and the key can be nmov!'d by turnlns i.t to th,. ri!Bht Cctockvin ) . tt II!Oif be necPssarv to vlg&t,. the auerinR, aLtghtly t.o u•ov~ 1ny preaaurt- from rl'w! ''t.on«Ut•• of the lock vhen unl~kSnfl,.

A) To c:oapletwtv remove • lock froe the fr01.e Teverae Lhe inat•ltation proeeedUTe.

E .~ ::J ;::'!ff

SERVICE MANUAL HANDLEBAR .IDJUSIMXIIT

MODELS WI'rnOUT FRO!It SUSPENSION NO SPECIAL TOOLS REQUIRED

'Ibe handlebar• on tbeae mohinea can be adjuetAtd fo-r beisbt only. To adjust the height on these, aee page 4.3, item 1), •bc:ken the ate• bolt. •• described and a.t the handlebar beisbt to required poaitlon . Tighten the bolt 1eeur.ly after ••ttins the handlebars and ~ke sure they are correctly centred 1n relation to the front wheel. MODELS WITH FRONT SUSl'ENSION

Only the handlebars on thoae machines that are NOT fitted with a loekins plate tnd bolt between the ''U" bolta can be adjuat.ed. -

The adjustment available on h1ndlebara without a locking bolt 1• for Teach and thit ia achieved by twiattns the btndlebn·a in the ''U*' bolt• afur ahckentne the ''U" bolt nuts, see Fig . 44-1, ~s• 44. After cbansins the h•ndlett-ar position it may be necttlary t o also change the levere for a 111on comfoTtable grlp position. The levert C!en be routed to any deai't'ed positlon by •lae'kenins the alotted ec-cev that pauea thl:ou,gb tbe. choke ltver on the left h1nd tide and the decompresaor lever on the right hand aide. Meke aure you tl.ghten the "U" bolt nuts and the lever alot t.ed screws .. eunly •fter 111kins adjuataent:s.

Illustrat~ belov are the typel of handltbara.

ADJUSTABLE FOR BliGHT ON1. Y

NON-ADJUSTABLE

ADJUSTABLE FOR REACH

NOTE A)

SERVICE MANUAL !OTTOH BRACKET ASSEMBLY

NO SPECIAL TOOLS REQUDtED

To dervice tbt bottom br1cket it will be neceeaary to complete the operation• on page 22 and 24 first.

NOTE B) As you vill see by the i lluetration on thi1 pas-. tht bottom bracket buahes are removable and replaceable. It t • very seldom neceuary to repllce the•• buehls and &ener•\1y t he only Service coni!Jti of cl~antng and giealing.

REMOVAL To remove the buthea dr1v• the111 out u.atns a haaDIIr and punch.

REFITTING To refit- tbe butbtl fira t "start" tlle bushes l.n the ~teket housin& by partially tapping them tn usi.ng 1 hardwood block. Coaplete t.natallatton can be done by passing a large bolt through the buahea, placing a Valhtr against tht outside of each bush first, then fitting 1 nut t o the bo lt and tighten up on the nut vhil e gripping the bolt M ad. Altern•tively , the bvshee can be pressed ln uling a bench press ot a bench vise .

- ,Q)

Fig. 49-1

hgo49

SERVICE MANUAL FREEY{EEL IUMOVAL AND 1\EFI'ITINC

SPECIAL 'lllOLS REQ!llltEil

FREEIIHEEL REMO\'ER # 17650 Tht fnevheel should be lubrl.c1ted from time to time to keep tt. running "'fr.e" and to prevent co'troeton .

Tht best 'Way to do th\.1 1s to rotate the cnnk• backwards •nd tt the same ti1De apply 1 fov dropt of SA£ 30 o1l to t~o odgo of the freewbeel at thl pO\nt "A" f1g , S0-1, "here the 110vin& outer rla of the freevtlttl t't•olve• over t.he fixed body of the freewheel. If the freevb!el ta vo~n lnd not ensastna v hen ptdalll.n& it vlll bo~ve to bt rtphct4.

1\EMOVAL 1) Remove the retr wheel as dtiCT1bed on paa• 28 and 28A . 2) Remove the

from right •~1• nutt and washer end cone lock h1nd alde of tbe axle.

nut

l) Pl1ce the fntvMtl removal tool tn tht bench vise .

4) Pbce the vhtel onr the fnevheel t'teov.l tool so tbe 1xle fl. tt into tbt tool and the lull on the tool •="Pat in the sroovtl 1n tbe freewheel bodt• s .. "ll" Fl&• SO-\ .

5) Hold ~he wheel !lr.ly pressln& downw1~d1 to keep the tool engaged in tht frefwheel and tutn the wheel anti-clockwise and un1crew the freewheel (rom the wheel hub.

REFITTING 6) U&htly lubttcatt tht threadt on the hub aOO acrt·v

the ne~ freevbetl on 11 far 15 possible by h1nd. 7) T~ deY free~tl will autoc~~ictlly tlshten ltaelf

on the bub after tbt vh4el is installed ln th• ~chine and bas been peda lled .

8) Refit the rear wheel 11 deaertbed on P•A• 28 and 28A.

Fla. SO-l

SERVICE MANUAL !J<CII<t A!ID FRA!IE SEI\IAL !~\NEBS

NOTE• Evtrr Cady b•• ao Enslnt and 1 fraae serial nuaber . -Thea~ are loeattd -

.. A .. The £nat.ne aerhl number ts on the left hencl •ldt of the cylinder bud,

••• Fis· 51·1. .

"&" Tbe Fra1111 eerhl number h stamped on tht left h1nd side of tbe frame,

••• n 8 • n-2. If a cylinder head or <::011plete e.natnt flat to be t'tphced, tbt enstne serhl n._ber pbtt aust be ttanlftrred to the nev bea-d or tn8lnt.

Pia.Sl-1 Fi&• 51- 2

-··

SERVICE MANUAL Lt!BRICATIO~

Rtauter Lubrlcatio~ is neceatary vherever there are ~vlns p.rtl that c~ in contact vlth uch otMr . TM' foll(lvtna h 1 aulde only 1nd should be adjusted dependi.ng on conclldona and YU&t•

Tht ••Jor lubrication points are It follows -

1) brake hvu pi vot bolts. s A E 30 oU Frtquency F.very month or Every 600 mUu (lOOO KM) 2) All Clbltt .. .. 3) DeeompTeaaor lever .. .. 4) Chokt lever .. .. S) Throttle cable. .. .. 6) re-ctah .. .. 7) Ink• 1r11 and cable nlppltl F tnt1 a. .. .. 8) ftnkt pivot bolts (cantilever bnke) .. .. 9) Klckattnd p1¥ot bolts .. .. 1 0) Freewheel .. .. Und•r extre.e operating eondltiont lubricate aore rrequtntly 11 requh'ed .

11) Pulley obo£t 12) ttltteoplc forks 13) Hub boorlnas 14) clutch boorlnss

lS) Cholno 16) Stter1ns head bearings 17) Botto. bracket axle

Kultl Purpose CTtt8t tvtry .. .. .. .. .. ..

MILES KM

1250 600

3700 1250

2000 1000 6000

2000

.. - or S~citl Chatn lube - aonthly .. Every .. .. 3700 3700

6000 6000

or

Under IXtteM operat:ln& conditions th• pa~ta requirins &l'ellt tllould brt ele1necl 1nd S'HIIId. •or• reauh~ly.

..

..

.. • .. .. .. ..

.. -

SERVICE MANUAL TECHNICAL DATA

£NC1NE I 2 Cyc1t H1 1 H. P. at 3000 R.P.M. M3 1 . 5 H.P. a t 4500 R.P.M.

CAPACITYo ~9.9 c.c . Bort 39 ma - Strokt 41.8 s

COIII'llESSIOSo 8 to 1

LU&RICATlONt &y Gal (Petrol} 1nd oil mtxture

CARBVRATtONt Cravity feed - !1xed jet - manual choke

CLUTCHt ot.oby double IUto.attc

8RAU:S ; Drum 70 1m1 dit - Can tl.llvtr

LICitTTNC1 Direct (D . C. ) Flyvbeel Hapt.o ~nerated

TIRES 1 16 x 2 Hoped Cutblon type

TUa£5 I

FUEL TA!OI:o

HORNt

TU!l~Co

FUEL CO"'SU!IPT I mil

PLUCS I

PLliCSt

PWCSt

PLUGS : PLUCS o

16 x 2 vltb SchTidtr valve. tube pressure• - Front 22 lba - Rear 26 lba. (avtrese rtdtr)

Capacity .614 Clllons

£leetrt.c

1.2 ana before T .o.c .

100 to 120 M.P.C.

HA~CIIAI. CT 35

&OSCK 636

A C 4l0Z

MOTOCRArt AE 32

CHAMPION l.B8A

-- -

SERVICE MANUAL MOTOR FAULT FINDING

In tbls section ~• wlll dtal ~th finding faults vhen th• ~tor will not start or run correctly or constantly.

Motor faulta can be broken down lnto two basic section& and these are FUEL PROBLEMS and ICNITtON PR08L£MS

Both of these problems can be dealt with systematically and for ~he most part will be found exte~nally. Before pulling the motor apnt to find a J>TOblem. follow the tnstructiont in tllia uction aod by a proceu oE elimination you witt most likely £lnd the fault ~lthout too much trouble.

From the outset, 1t 18 necessary to determine whether the probltiD 1s f!:!E:. or IGNITION and the ~st way to check this is ~o proceed ts follows -

HOTOR DOllS NOT START o< HARD TO STAI\T

1) Remove the plug lead and cap from the sp~rrk plug, remove the spnk plug snd inspect it. If the plug is wet the problem is most likely"tGNITION". If the pltJg i.s dry the problem i s tJost likely "FU£1.",

CHI:CKlNG IGNITION PROSLEliS

T~o external paTte to check 1n the follO\i'lng orde1: ere ... A) The Spa-t·k Plug 9) The S par'k Plu& Cap

C) The II. T. Plus Lead D) Tbe H.T. Coil E) T~• Magneto f) The H.T. Feed 'nre: CHECKING FOR SPARK

l) Re•ove the spark plug from the motor, attach it to the plus cap and ltY it on the cylinder head fins (grounded) 2) Rotate the mot-Or by turnin& the p-edals and cbeek for a spa-rk at the plu.g.

3) If no spa~k, replac~ tbe apark plus and cheek aeatn. 4) If et\11 no spark re~lace the plus cap (vhte h contains an interference supreator} and check for spark again.

Continued on next page.

SERVICE MANUAL MOTOR FAULT FTNDING

If st:i.ll no sp~;rrk replace the H.T . plug lead and check again. The plug lead has a long and • sho'tt connecting end and tbe long ttnd fits into the H.T. CtOU and the short tnd into the plug cap.

) If stlll no spark remove the H.T. coil. Att.ch a new coil to the H.t, plus lead and a ttach the H. T . feed vi r:e fro• the masnet.o to the coi.l. Place ·the H. T . Coi 1 on the oyl iOOer betd fins so one of the mounting sc~ews is wedsed in tbe fins (grounded) and check again for spark.

1) lf still no spa~k, double check the proceedure ltemi 1 through 6, before lnipectlng the magneto. n The thins• t0 look for when double cheeldng are -

8-1 -The plug being srounded properly. a-2 -The H:r. plug lead pro(:Htrly connect~ to the pl.ug, CIP auld H.t. coU. 8-3 - The H :r. feed wtre properly conneceed - also check t.tle cover of the w·h:e froiD the H. T, CoU

to the magneto plate for damage or fractu-res and posstblo .. shorts". J) If still no sps~k it will be necetaary to ln1peet th~ masneto as follow•-

9-1 -Remove t-he double clutch, see page 9 . 9-2 -Remove the flywheel, see page 11 . 9-3 - With the magneto ~xpo•ed check for the following possible problems . 9-4 -The points ate opening and closing by rotating th-e engine . cheek p-oint.a saP~ see, page 12. 9~5 -Check for st!eklng contact breaker points ot moving breaker arm stiff -remove and clean

ard lubricate shaft with a s~ar of graphite oil. 9-6 - Check all the wir~s for ebafins and possible s~ortlng to ground and ~bbtng on the flyvheel. 9-7 - Check t he points for burning and clean or r~pl~ce ts OGecs&ary. 9-8 - Remove and replace th~ condenser. 9-9 -Cheek for oil 1eepage froo the crankshaft (denotes oil seal damaged) . Cleaning the oi l f~om

points and magneto -will effect a umporary tep.tit' but not eliminate the problem . 9-10- Cheek the flyYheel for demage - possible loose magnets. 9-11- Check for demagnetized flywheel (VERY 1\ARE) by replac1ns with a new one. 9-12- Ch~ck H.T . Coil bf repl acins wi~h new one (NOT COMMON)

RESISTANCE TEST FIGURES

COILS U. T. FEED COIL # 19949 Ot q 21994 o .5 OIIIIS

LIGHTING COil. 6 19948 1 . 0 OHMS

" •• u 21995 1 .8 OfiMS

SUPPRESSOR I» 20451 4000. OHKS (in plug cap)

CONDENSER # 19067 0.15H. F.

Continued on next page

SERVICE MANUAL MOTOR FAULT FINDING CHECKING nJEL PROBLDIS Alvaya r .. eaber that the fuel vhicb reacbea the CTlindtr 11 a eoablnation of Caa (Pet~ot) and 011 end Air tnd lf thla alxture ta upset by any ... aa tbe eotor vtlt not perfor. correctly. Any fUel probleaa V\11 involve - Tbe F'uel Tank- 1bt FUel Tap -The Cerbut'ettor end ultiaately the Rotor.

A nu.ber of poulble problnt ate dea:cTlbed on paaee )7-38 1nd 39 and it 1$ vorth revlewtns tbla tecdon be!on proceed in& v1 th the follovlns -

NOTE• The carbunttor is of the gravity feed type .nd the ehtu-re 11 conttaat •• there h no ptovh\.on f'Or"a tJiA~ or RICH •lxture and. the fuel 11 aeterflt by 1 r•ph<:tttble jet .

The s•• (petro1) end oil mixture ta 1 ratlo of 2S pittl se• (petrol) to 1 part oll , when utlna rt&Uler TWO CYCLE or 2 STRatE o11a of top grade. A et.xtul't or 40 ~rta goal (~trol) to 1 Pitt oU coen ~ Uttd lf ESSO ULTRA MARINE OIL ts available .

Any .,Resull-r" gu (petrol) 1e uthflctot:y or "Prem11MII" fut~la mty be used . Non lt1dtd gu (ptaol) h 1110 IOCtpttble.

2S to 1 RATIO (4%) • 6,4 ozs. oil to 1 IMPERIAL CALLON CAS (PETROL) 40 to 1 RATIO (2.5%) • 4 oza, oll to 1 .. .. .. .. 10) Hake 1ure tbtr. is fuel in the t•nk, see P•1•1 37-la-u. tl) Hake lUTe tht·n 1a fuel reaching tbe earburtttor, ••• 'P'&'!I 37-18-39 12} tr the aotor ~~ bad const~erablt use 1nd l• btrd to attrt or ldles poorly, check Cor carbon

bulld up ln tht exhaust port .00 ex.bauat pipe 1~ cbeck tbe ~fler 1a not blocked. Stt PI&• 11.

ll} If thtrt \a exceuhe carbon cheek the Cuel alxture h correct . Drain the unk •nd pour l.n about I plnt O( futl 70U knov 11 the proper ahtun and run the aotor .

14) Check thlt the carburet-tor b fitted ti&ht Qnto the tnuke pipe atd the lntelile plpe 11 tl!,ht on ~ cyllndet: e t tbe a antfold.

\5) Check the mt111fold s•sket - replace 1f neceatuy. tr tbe intake plf>4 is looae o-r the s••q.t da•ased the aotot vill drav ln extrl tlr end upaet t~ mlxtUTe.

16) Check the fuel filter• 1nd jet fOT ctosstna. •e• pa~•• 37-38-39.

17) Check that the cyUnder 1a tight 1nd cylinder but s.uket not du~•eed ... the motor w111 dnv 1.n excee-s •b: It th1.1 point tho, -- u well u loll itt ennkeaa:e compreaston .

18) Check cbtt ttle cylinder hea-d 1a ti8bt 1nd tilt htad £lllc.et in good condition. CeY1tratly tf' there ll • tn"Oblta in th11 lt:·ea you c•n hen tbe pnuure e~eap1ns.

\t) Check the jolnin& of the oro ct:ankc••• htlvea for 1ny leaks of fuel •nd if neceaury tlshten the C'ttnkcut boltl (7 Allen type hex bolt.l). If the et:lnkcut subt 11 d .. a-d it vlll be neceaury to atrlp tM en.stne to replace it. It la .,.ry raH that tht 1 occura.

p_, 56 Contlnu~ on out P-ISt

SERVICE MANUAL MOTOR FAULT FINDING-

OntER POSSIBLE MOTOR PROBLEMS

Having cheeked the IGNITION and FUEL and if the motor etill dote not run properly check tbe followtns list for the most li~ety c•~•• of the problee.

Poor Motor Pe~foraance

20) Check fuel mlxture. 21) Check apork plue. 22) Check colour of. spaTk, tt should be blue, tf it is orange check the potnta for - buTnin& - gap or dirt ,

if still orange replace tbe condenser.

23) Check the timing - see page 13 and 14 . 24) Double eheek for carbon build up, tee page 18. 25) Check ddve belt for tension, see page 8.

26) Che-cl< chain t.ention, see page 21. 27 ) Check tire preesurts (eould be too low).

28) Check the brakes are not over adjusted.

If e motor runs in reverse the timing needs adjusting, ••• pege• 13 •nd 14. This is usu1lly CIUSed by t he masneto cam improperly installed during after service. 29) Check that the cr•nhbaft i.s not bent - this can be visually checked by turning tbe QOtor over and

observing the double clutch and flywheel. If bent ch! crankcase ass-.bly ~111 bave to be replaced. R~roember th4 crankshaft controls the magneto cam and tf bent it is not possible to obtain correct ignition.

30) Check for worn crankcase bel rings ( side play on the ounksb.aft).

31) Check for cylinder 1nd piston tins wear . Nohy Motor !2) Cheek for eylind•r and plteon ond pllton rlng wear. 33) Ch•ck connecting rod be•rings for ve1r, both tbe b1s end and ~•11 end.

34) Check for looat muffler. 3S) Check for looae engine mounting bolts. 36) Check for main bearing wear. 37) Check for clutcb be1ring wear and poaaible dacage from impact 1nd also for bent crankshaft. 38) Check for broken mounting bncket MCOMMON).

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